Hello tnttt! I've been browsing the site for a while and have gathered many ideas from here, so thanks to everyone who has posted their builds and ideas. They're very helpful.
I recently started my own build and thought a thread to document it was in order. It's going to be a 5'x12' 2+2 benroy with some 33" tires to match the tow vehicle so I can use its spare if needed. The +2 will be bunks that convert into a couch kind of like the camp-inn 560. I've been through a number of designs but have made a final decision on the overall shape and size. Details like kitchen and interior storage are still up in the air though. I also keep going back and forth on whether or not to build storage under the main bed and whether or not to have a water tank system and sink. We'll see.
So, on with the pictures. Here's the design so far.
Went to the steel yard and picked up a trailer "kit."
A little cutting and measuring and my brother and I are ready to start welding in 98 degree Texas heat. We like to start all our welding projects in the middle of summer. Builds character?
My original design called for an angled front to an expanded metal walkway along the perimeter of the trailer, but I think we were delirious from welding in the heat and made them square. I might cut the square edges off and fix it. I haven't decided how much I care yet.
And this is where we wound up at the end of the first weekend. The tire is mocked up in this picture as etrailer and I are not on the best of terms. It's been over a month since I ordered a Timbren axle (or lack thereof?) from them and it keeps getting delayed. I finally cancelled today and ordered from another vendor that actually has it in stock.
This past weekend was spent making fenders. I couldn't find any big enough that I liked so I made my own. They're probably overkill but I want to be able to stand on them if I add a roof rack in the future.
I decided to make them bolt on so I can remove them to build and skin the walls.
I also added some gussets to bolt the floor to the frame. The rear ones are extra large so I can mount stabilizer jacks there too.
And that's where we are today. I have a few details to finish up like safety chain attachment points and drilling bolt holes to mount the floor, but once I get the axle in I'll be mounting that and then painting the trailer in POR-15. Right now I'm planning on rolling/brushing it on since it's supposed to be nasty stuff, but I'm not sure how well that will work on the expanded metal. I might change my mind and wind up spraying it. We'll see.