M116A3 Build

[lfhoward]

I had a chance to spend a few quality hours with the trailer today.
I got some more styrofoam insulation cut to shape and installed. I also installed one of the interior wall panels - an 8' X 1' long section of plywood that goes beneath the right side bench. I also found out that my 1000 watt pure sine wave inverter is a very good one, as it powered my router as I trimmed the top edge of that piece of plywood flush. That router draws some serious amps, so I was pleasantly surprised by the result!

[lfhoward]

It's nice to chip away at the project little by little as I have bits of time here and there. The interior is a place where I can work on some small stuff. Coming up, some smaller projects include:
- installing the wall below the left side bench (like what I did today on the right side).
- installing support rails along the benches for the removable bed slats.
- building and installing folding bench seats that convert into the bed surface/frame.
- building the "dashboard" above the headboard area. This strip will have DC power outlets, AC household plugs, the switch to turn the inverter on and off, and the remote display meter for the solar system and batteries. It'll also incorporate a small shelf for glasses and books.
- installing cedar planks for the interior walls.
- building DIY trim rings for the two front windows.

Bigger stuff that will take more time & good weather includes:
- skinning, of course.
- installing the tongue/battery box, and running conduit back to the trailer for main wiring.
- installing the solar panel permanently on the roof.

[S. Heisley]

I can hardly wait to see pictures; but, I know that PA has snow and you're probably up to your neck with it about now.
Another month and spring will be getting close!

[lfhoward]

I can hardly wait to see pictures; but, I know that PA has snow and you're probably up to your neck with it about now.
Another month and spring will be getting close!

3-5 inches for tonight! Most of that 22 inches from our previous storm has melted away, so it isn't exactly neck deep at the moment. It sure is easier to go outside and work on the trailer when it isn't snowing or freezing, though.

I'll snap some photos of the interior the next time I'm out working on it. Thanks for following my thread and for your encouragements!

[lfhoward]

I found a 20% off coupon for a well known auto parts store, and ended up purchasing the 30 inch aluminum ATV tool box I linked to earlier. $110 including free shipping! I can't wait to install it on the trailer tongue and get the batteries out of the cabin!



Does anybody have any good solutions for mounting tongue boxes (I'm thinking rectangular U-bolts)?

Has anyone used flexible conduit linking a tongue box and a trailer, so that both stay waterproof?

Cheers, and thank you,
Lauren

[lrrowe]

I am considering a box like this and my idea so far is to make a frame out of angle iron for it to sit in and weld that frame across the tongue. The box can either be bolted or welded to the angle iron frame. My plan would also have propane holders on each side of the box. But then again, I have the trailer width to handle it.

May I ask where you got the box?

[lfhoward]

I am considering a box like this and my idea so far is to make a frame out of angle iron for it to sit in and weld that frame across the tongue. The box can either be bolted or welded to the angle iron frame. My plan would also have propane holders on each side of the box. But then again, I have the trailer width to handle it.

May I ask where you got the box?

AutoZone. There is a deal for free shipping and 20% off a ship to home order today (ends at 11:59 PM). The code is shown on their website's home page, and is LOVEAZ20.

I bought a Better Built/30 in. ATV box, Part Number: 67011387. I was in the store today and asked about the measurements (30 X 12 X 12 inches), because those numbers are not listed on the website. It should be able to fit 3, group 24 batteries (7 inches X 11 inches footprint) as long as the opening is large enough. Fingers crossed on that! Otherwise, I think plan B is it will end up as a storage box for my air tools in the garage.

[pchast]

I'm having trouble with my tongue box shifting with u-bolts and intend to drill screws directly into
the tongue before we use the pod again this spring.

[lrrowe]

I am considering a box like this and my idea so far is to make a frame out of angle iron for it to sit in and weld that frame across the tongue. The box can either be bolted or welded to the angle iron frame. My plan would also have propane holders on each side of the box. But then again, I have the trailer width to handle it.

May I ask where you got the box?

AutoZone. There is a deal for free shipping and 20% off a ship to home order today (ends at 11:59 PM). The code is shown on their website's home page, and is LOVEAZ20.

I bought a Better Built/30 in. ATV box, Part Number: 67011387. I was in the store today and asked about the measurements (30 X 12 X 12 inches), because those numbers are not listed on the website. It should be able to fit 3, group 24 batteries (7 inches X 11 inches footprint) as long as the opening is large enough. Fingers crossed on that! Otherwise, I think plan B is it will end up as a storage box for my air tools in the garage.

Thanks. I will add this to my list for future consideration.

[lfhoward]

I like weekends with beautiful weather! 60 degrees F today. Got me in a trailer building mood...

... So I came home from HD today with pretty much everything I need to fix up the interior. There will be Pacific knotty cedar planking on the walls. I am still working out whether I want the 3.5 inch wide tongue and groove cedar planks to be diagonal or vertical. There will be light birch plywood on the ceiling. And the side benches that convert into a queen size bed frame will be made of pine boards, but with oak bed slats to hold it up. The "dashboard" across the front will be made of select pine.

The workshop smells amazing with all that new wood in there. Makes me want to get back to woodworking!

[lfhoward]

It's been a long time since I posted pictures, so here is what the trailer looks like today.

First, this is the pile of wood that makes my workshop smell amazing. From left to right: oak bed slats, pine boards for the convertible bed/benches, knotty cedar planks (1/4 inch thick with tongue and groove edges), pine for interior trim. Behind is pine plywood which is hiding birch plywood and 10 sheets of white 0.04 aluminum.


I've been working on building window frames for the interior that need to be in place before I can put the cedar planks up on the walls. Parts being prepped:


And assembled:


Here is the new battery box sitting on the trailer tongue:


It's nice and deep and should have no problem holding three batteries. A fourth battery could fit, but I am not planning on getting another one.


Here is the gap between the trailer and the box that will need to be spanned by some sort of flexible conduit. The gap is about 8 inches wide. I'm open to suggestions, but am looking at the conduit used on outdoor air conditioners and household generators.


Here are some interior shots. This one shows the batteries temporarily housed indoors.


Here is a closeup of the port side shoe cubby. The outlet hidden in there is to run a space heater in cold weather (connected to shore power or a generator).


The rear door without the interior paneling. You can see my DIY trim ring for the window. One of the rectangular frames in an earlier photo will secure the trim ring and the window firmly to the door.


The solar panel is a good size for the width of the roof. The cables will go through the roof using waterproof glands, but for now the open door works well!


The solar panel brought the batteries to near full, so the charge amperage at the time of this photo is suitably constrained to a trickle even though it is very sunny out.


Finally, here is a photo of the trailer taken last fall so you can see the overall shape of the build. Today the trailer was covered by a blue tarp.


Not too far off my original sketch!

[lrrowe]

Looking very sturdy.

[S. Heisley]

You've gotten a lot done and it's looking great!

You are probably still okay; but, hopefully, you are watching your trailer's weight.
If your Jeep is like mine, it has a limit of 2,000 lbs, trailer stopping ability, even with brakes.

[lfhoward]

Thanks Bob and Sharon! Sharon, looks like we do have the same vehicle, the Jeep Liberty. Mine's a 2008. It has the tow package with the auxiliary engine and transmission cooling so it can go up to 5000 lbs load. I am hoping my trailer won't be much more than 2000 lbs when done (it's 1000 lbs for just the military trailer itself, with a 3150 lb GVWR), but I'd have to take it to a truck stop scale to be sure. I'll do that once it's skinned (0.04 Aluminum sheets are heavy) and I have the interior walls on-- I am curious about its weight too. When pulling the trailer, I have to keep the Jeep in tow/haul mode to lock out 4th gear, so I definitely know it's back there. The trailer has its own brakes, so luckily the Jeep doesn't have to do 100% of the stopping on its own.

[S. Heisley]

Thanks Bob and Sharon! Sharon, looks like we do have the same vehicle, the Jeep Liberty. Mine's a 2008. It has the tow package with the auxiliary engine and transmission cooling so it can go up to 5000 lbs load.

Mine is a 2009 Jeep Liberty with the tow package, etc. According to the manual, it will brake/stop no more than a 2000 pound trailer safely. Just to be certain we are on the same page, that is not the same as towing/pulling load. I'm told that it has something to do with the Jeep's short wheel base, although newer Cherokee Jeeps supposedly can tow/stop more. The army trailer puts you at a weight disadvantage; but, since you are building light.......As long as you don't go crazy with wood, etc, hopefully, you'll be okay and stay below 2000.