Ozarks Jeep Thing Club
Public Forums => Fabricators Forum => Topic started by: Cook5 on 12/22/12 - 02:11PM
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Guys, Being new to the club, I apologize if this has been discussed but has anyone built a camping trailer for their Jeep that worked out well? I'm starting a project to build one and am looking for ideas/feedback. I plan to base it on the Jeep trailer made by Livinlite. I have the tent portion and have ordered the aluminum for the box & frame. I've also ordered a Dexter torflex axle for it. I'm going to use the old 33" tires I took off my jeep for it. So...Feedback? Ideas?
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don't use old tires.
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We will all be watching your build! There are a lot of members interested in build!
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The tires aren't old, just the ones I took off my TJ. Cooper Discoverer 33's. Probably have 5,000 miles on them. I'll try to post some pictures of the plans I've got put together if I can figure out how to do that.
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Here's a drawing I'm working from, I have several more that I've done but still have to figure out how to integrate them.
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I finally got some time to work on the trailer. I have the aluminum for the frame, the axle, the tires/wheels and the tent portion all in-hand. Today we mounted the tires/wheels to the axle, cut all of the frame pieces out, welded the frame together and mounted the axle to the frame. I now have a rolling chassis. I still need to get the hitch in order to be able to pull it. Hopefully we can start next week on framing up the box and building the lid. Attached are some pictures of the frame build-up. In these pictures, we mounted the wheels to the axle & cut the frame pieces and started the box of the frame. We spent quite a bit of time making sure everything was perfectly square.
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Tires.
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This is the sketch I made for the main frame we'll be working from.
(http://imageshack.us/a/img849/958/2813313.jpg) (http://imageshack.us/photo/my-images/849/2813313.jpg/)
**These are the tires off my Jeep. 33" Cooper Discoverers
(http://imageshack.us/a/img14/318/tiresi.jpg) (http://imageshack.us/photo/my-images/14/tiresi.jpg/)
(http://imageshack.us/a/img32/7361/tireswsize.jpg) (http://imageshack.us/photo/my-images/32/tireswsize.jpg/)
**Tires/wheels mounted on the Dexter Torflex Axle
(http://imageshack.us/a/img715/527/tiresonaxle.jpg) (http://imageshack.us/photo/my-images/715/tiresonaxle.jpg/)
**Here is the pile of aluminum stock I am working from. All of the frame is 2X3" tubing 1/4" Thick
(http://imageshack.us/a/img585/9651/pileofaluminumstock.jpg) (http://imageshack.us/photo/my-images/585/pileofaluminumstock.jpg/)
**We decided to miter the corners to make them stronger
(http://imageshack.us/a/img202/1623/mitercorners.jpg) (http://imageshack.us/photo/my-images/202/mitercorners.jpg/)
**We used a miter saw with a special blade to cut all of the aluminum stock
(http://imageshack.us/a/img593/482/cuttingmiterjoints.jpg) (http://imageshack.us/photo/my-images/593/cuttingmiterjoints.jpg/)
**A fair amount of time was spent making sure the frame was perfectly square
(http://imageshack.us/a/img20/8660/squaredframe.jpg) (http://imageshack.us/photo/my-images/20/squaredframe.jpg/)
**We welded all of the joints using a MIG welder with an aluminum spool gun
(http://imageshack.us/a/img688/9011/weldedmiterjoint.jpg) (http://imageshack.us/photo/my-images/688/weldedmiterjoint.jpg/)
**Once we got going, the frame assembled pretty quickly. 4 Hours from the pile to a rolling chassis!
(http://imageshack.us/a/img441/5405/assemblingframe.jpg) (http://imageshack.us/photo/my-images/441/assemblingframe.jpg/)
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**Here we're putting the tongue together.
(http://imageshack.us/a/img543/6291/2813290.jpg) (http://imageshack.us/photo/my-images/543/2813290.jpg/)
**We welded the tongue tube to the bottom of the frame attaching to 3 cross tubes**
(http://imageshack.us/a/img826/5472/2813292.jpg) (http://imageshack.us/photo/my-images/826/2813292.jpg/)
**We gussetted the tube for the tongue where it attached to the frame with 1/4" angle to help strengthen it**
(http://imageshack.us/a/img198/8138/2813295.jpg) (http://imageshack.us/photo/my-images/198/2813295.jpg/)
**Here the frame is basically assembled. We gussetted the front corners to strengthen them as well. Just need to weld it all up!
(http://imageshack.us/a/img15/8076/2813294.jpg) (http://imageshack.us/photo/my-images/15/2813294.jpg/)
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**Welding the axle mounts in place**
(http://imageshack.us/a/img705/8113/2813299.jpg) (http://imageshack.us/photo/my-images/705/2813299.jpg/)
**Axle mounted!! We measured front to back from both sides of the axle to make sure it was perfectly square with the trailer so it will track straight**
(http://imageshack.us/a/img716/8971/2813297.jpg) (http://imageshack.us/photo/my-images/716/2813297.jpg/)
(http://imageshack.us/a/img248/2063/2813298.jpg) (http://imageshack.us/photo/my-images/248/2813298.jpg/)
(http://imageshack.us/a/img856/7869/2813307.jpg) (http://imageshack.us/photo/my-images/856/2813307.jpg/)
**Done for the day. We started with a couple of wheels and a pile of aluminum stock about noon and by 4:00PM we had a rolling chassis. It went better than I expected, the miter chop saw made a huge difference in the cuts. It saved a ton of time. I think the frame/axle assembly probably weighs in at around 400lbs. Target weight for the empty trailer is 800lbs. If anyone has feedback or ideas, I am open since this is my first stab at this.**
(http://imageshack.us/a/img834/6816/2813304.jpg) (http://imageshack.us/photo/my-images/834/2813304.jpg/)
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Looks good! Is the trailer a 5' x 10' ? and what are you going to use for flooring?
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Looks great! Can't wait to see the finished product!
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The box of the trailer will be 60"X78", I added 18" to the front of that for a pull-out kitchen/storage box. So the overall frame is 60"X96" plus the tongue. The floor will be aluminum plate that we'll put rubber matting on top of. Using the aluminum keeps the weight down and avoids any future rusting problems. At this point, I plan to have A/C, heat, lights, a bench seat inside and a cook stove and small sink and possibly a small fridge in the pull-out drawer outside. I'm debating whether to add a zip-on screen room or not, probably will do that later.
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Have you decided on the tent yet? Or is it going to be an enclosed trailer?
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I have the tent portion. I ordered it from the company that builds the Jeep branded trailers. It is exactly the same without the Jeep logo.
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I've had a couple of people asking about cost on the project so I'll post this information I sent to them. I spent a lot of time over several months researching and planning so if anybody is interested, you're welcome to any information I have regarding a trailer/camper project. I'm sure some of you have checked on the trailers and know they are expensive so here's what I used to analyze which way I was going to go. Just what I decided, it won't be right for everyone.
I don't mind sharing information at all. That's why I'm posting everything on the forums. I started out with the premise that I wanted to have a camping trailer I could pull behind my Jeep. We do a lot of camping, always have, I have a son that's been in scouts since he was 7 and now is in Venture Scouts along with his older sister so we're always out somewhere. After deciding that I wanted a trailer, I started looking at the different brands, AT, Tentrax, Livinlite, etc. There are dozens of them. I liked different features of all of them. I didn't like the prices of any of them. The Jeep branded trailer made by livinlite is what I decided to base my trailer on since that would allow me to actually have a trailer I could stand up in, have a meal in if the weather is bad and will also allow for heating & A/C. Most of the rest of the offroad campers use a rooftop tent of some sort. That being settled, with the base price of these trailers starting at around $11,000, I figured if I could build one for half that, it was worth my time. So here's the budget I put together. I figure to have about $4,000 in the base trailer and then we'll see how much we add on in amenities.
Aluminum for frame, skin, etc. $1,800 (My brother has a trailer fab shop so we ordered it wholesale)
Axle & trailer jack $200 (I ordered this through Redneck with a commercial account)
Tires/Wheels $300 (I had the tires already so they're not included)
Tent upper section $450 (I bought this directly from the tent manufacturer)
Offroad hitch $250 (I ordered a max coupler from AT)
Catalytic heater $250 (I haven't actually bought this yet)
Partner cook stove $220 (Ordered online)
A/C unit $700 (Yet to acquire but will have to get it soon)
Total $4,170
Most of these are actual numbers as I've already bought most of it. I'll also spend a hundred bucks or so in welder wire and tips plus I'm going to have the trailer sides powder-coated which will probably add a couple hundred bucks. Again, if I get in for half the retail considering I'm going to have much more amenities, I'll be happy. Bear in mind that I've got a good shop to do this in and already have the welder and tools necessary.
Let me know if this helps or if you have any more questions.
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What kind of AC unit are you going with? Regular RV AC? Do you have a link to the tent you bought?
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I haven't decided on the A/C yet except that it will have to be a through the wall unit instead of the typical RV rooftop unit. I've got it sized at 6000BtuH. The tent is made by a company called Veada, they make tents, bimini tops & seats for boats. When I checked though I actually ordered it through Livinlite. Just called them up and asked for the parts department. livinlite.com (http://livinlite.com)
If you go to the Livinlite web-site and look at the warranty information, they list all of the manufacturers for their products with contact information.
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I did get some time this weekend to work on the trailer. Fabbed up a rear receiver hitch so I can plug in a carry-all or a bike rack. Also spent quite a bit of time working up the hitch (I got the max coupler hitch in). That involved quite a bit of cutting, welding, grinding and painting. Basically the 2X3 tubing we made the frame out of didn't work well with the hitch. So I got a receiver tube and cut out some plates from carbon steel to weld to the receiver that would allow me to bolt them to the tongue. Since the tongue is aluminum and the receiver is carbon, I would have to build brackets and bolt them together. We also put some 1/4" aluminum plates along the tongue to help gusset it since this is where all of the stress will be exerted. At the same time I mounted a jack with a dolly wheel and installed the safety chains. The jack had to have a bracket built for it so it could be bolted on that way I can change it later if it gets damaged. I also cut all of the wall studs to length so that portion will go faster and we installed half of the flooring (1/8" aluminum plate) stitch-welding it to the frame. The flooring is smooth aluminum sheeting but will be covered with a rubber mat. It took more time to make the hitch brackets than it did to build the entire frame. By Sunday afternoon I was able to actually pull the trailer down the road a bit to see how it tracks and to check the hitch height to make sure it would all be level.
Here is the rear receiver mounted under the trailer.
(http://imagizer.imageshack.us/v2/xq90/43/20130214165358.jpg) (https://imageshack.com/i/1720130214165358j)
We made these 2 crossmembers to bolt the receiver hitch to. The hitch is an old one from a truck I had. We welded the crossmembers in flat to allow room for the bolt-heads to miss the floor decking.
(http://imageshack.us/a/img39/9318/receivermount.jpg) (http://imageshack.us/photo/my-images/39/receivermount.jpg/)
(http://imageshack.us/a/img14/3935/receiverweld.jpg) (http://imageshack.us/photo/my-images/14/receiverweld.jpg/)
Here is the hitch I purchased.
(http://imageshack.us/a/img198/5613/maxcoupler.jpg) (http://imageshack.us/photo/my-images/198/maxcoupler.jpg/)
Here's the coupler against the aluminum tongue showing the size difference necessitating the brackets.
(http://imageshack.us/a/img171/3997/couplertongue.jpg) (http://imageshack.us/photo/my-images/171/couplertongue.jpg/)
(http://imageshack.us/a/img209/5854/20130216095409.jpg) (http://imageshack.us/photo/my-images/209/20130216095409.jpg/)
My receiver tube & aluminum spacers/gussets. The gussets will be welded to the tongue and will space the tongue properly for the hitch and also gusset the high-stress area.
(http://imageshack.us/a/img685/8857/hitchreceiverspacers.jpg) (http://imageshack.us/photo/my-images/685/hitchreceiverspacers.jpg/)
Sketch of the brackets to be built.
(http://imageshack.us/a/img209/3807/hitchplatesketch.jpg) (http://imageshack.us/photo/my-images/209/hitchplatesketch.jpg/)
Brackets tack-welded to the receiver tube.
(http://imageshack.us/a/img600/4908/receiverplates1.jpg) (http://imageshack.us/photo/my-images/600/receiverplates1.jpg/)
We welded the new brackets to the receiver tube, then ground all of the welds down for aesthetic reasons. It also helps get a smooth paint job to hopefully help prevent rust.
(http://imageshack.us/a/img221/5517/kentgrinding.jpg) (http://imageshack.us/photo/my-images/221/kentgrinding.jpg/)
After welding & grinding, we used an upright mill to bore 4 holes through the brackets & spacers so everything would match up exactly. After it's complete, we'll clamp it to the tongue & drill through the tongue.
(http://imageshack.us/a/img715/4527/drillingreceiverplates1.jpg) (http://imageshack.us/photo/my-images/715/drillingreceiverplates1.jpg/)
The receiver & brackets received multiple coats of primer & paint & clear-coat. Hopefully it will keep it from rusting.
(http://imageshack.us/a/img651/7758/paintingreceiver1.jpg) (http://imageshack.us/photo/my-images/651/paintingreceiver1.jpg/)
While waiting for the paint to dry, we used the time to cut the floor plates out & stitch weld one of the sheets to the trailer.
(http://imageshack.us/a/img585/1854/flooringstitchwelds.jpg) (http://imageshack.us/photo/my-images/585/flooringstitchwelds.jpg/)
(http://imageshack.us/a/img855/9259/20130216151900.jpg) (http://imageshack.us/photo/my-images/855/20130216151900.jpg/)
One sheet of flooring installed.
(http://imageshack.us/a/img802/2067/flooringinstalled.jpg) (http://imageshack.us/photo/my-images/802/flooringinstalled.jpg/)
(http://imageshack.us/a/img705/8025/stitchweld.jpg) (http://imageshack.us/photo/my-images/705/stitchweld.jpg/)
Jack & hitch attached to trailer.
(http://imageshack.us/a/img688/9897/jacknewhitchtopview.jpg) (http://imageshack.us/photo/my-images/688/jacknewhitchtopview.jpg/)
(http://imageshack.us/a/img23/6618/hitchjeep1.jpg) (http://imageshack.us/photo/my-images/23/hitchjeep1.jpg/)
First trip down the road, it sits very level and pulls straight. Whew!!
(http://imageshack.us/a/img820/2624/trailerbehindjeep.jpg) (http://imageshack.us/photo/my-images/820/trailerbehindjeep.jpg/)
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Spent a few more hours working on the trailer this weekend. The goal was to get all of the walls framed up so I could start wiring/plumbing this coming weekend. The framing portion goes much quicker than the small fab projects. The walls did get finished and I started to work on the fold-up stairs to get in the thing. I had picked up the appliances and a fresh water tank prior to this so I would know how much room to leave open in the walls. I also stretched the tent over the frame to mark out exactly where the door opening in the tent is.
Heating & AC Unit I bought.
(http://imageshack.us/a/img199/4902/furnaceac.jpg) (http://imageshack.us/photo/my-images/199/furnaceac.jpg/)
Checking the clearance in the back wall for the furnace. It has a plate for the exhaust and the combustion air.
(http://imageshack.us/a/img809/1764/furnaceclearancecheck.jpg) (http://imageshack.us/photo/my-images/809/furnaceclearancecheck.jpg/)
I decided to put a fresh water tank in and it will fit under the bench seat with the furnace. Should help it in cold weather too.
(http://imageshack.us/a/img835/73/furnacewatertank.jpg) (http://imageshack.us/photo/my-images/835/furnacewatertank.jpg/)
I'm planning to put the AC unit in the side wall on a pull-out shelf with a door to seal it when not in use.
(http://imageshack.us/a/img199/8793/acclearancecheck.jpg) (http://imageshack.us/photo/my-images/199/acclearancecheck.jpg/)
We are starting to frame the rear wall first. I cut all of the studs earlier so it went pretty quickly. The slowest part is squaring every one as we tack it in place.
(http://imageshack.us/a/img854/5/rearwall.jpg) (http://imageshack.us/photo/my-images/854/rearwall.jpg/)
The walls go up pretty quickly after it is all squared up.
(http://imageshack.us/a/img844/678/startingtoframewalls.jpg) (http://imageshack.us/photo/my-images/844/startingtoframewalls.jpg/)
After tacking everything together & checking for square, we welded each stud at the bottom & top.
(http://imageshack.us/a/img6/8439/studweld.jpg) (http://imageshack.us/photo/my-images/6/studweld.jpg/)
We mitered the corners of the top rail, then welded them and ground the welds down for a smooth joint.
(http://imageshack.us/a/img854/8476/miteredcorner.jpg) (http://imageshack.us/photo/my-images/854/miteredcorner.jpg/)
(http://imageshack.us/a/img705/7697/finishedcorner.jpg) (http://imageshack.us/photo/my-images/705/finishedcorner.jpg/)
This is the framed opening where the entry door will be. I left the top rail in place to help keep everything square while we welded it up. I'll cut it out later.
(http://imageshack.us/a/img694/2504/dooropening.jpg) (http://imageshack.us/photo/my-images/694/dooropening.jpg/)
The walls are all framed up.
(http://imageshack.us/a/img836/7849/studsallin.jpg) (http://imageshack.us/photo/my-images/836/studsallin.jpg/)
(http://imageshack.us/a/img35/4964/wallsdone.jpg) (http://imageshack.us/photo/my-images/35/wallsdone.jpg/)
Next up is plumbing the water line, propane line and wiring the trailer. That will hopefully all happen this week/weekend. Then I'm going to skin the inside of the box and have it spray-insulated. After that, skin the outside and bottom and powder-coating. Everything takes longer than you want it to but that's the way it goes.
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I forgot to post the picture of the steps I started to mock up. The plan is for them to fold up and I'll remove them when not in use. I didn't want them under the frame where they could get banged up.
(http://imageshack.us/a/img803/6184/laddermockup.jpg) (http://imageshack.us/photo/my-images/803/laddermockup.jpg/)
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Lookin' good! I'm enjoying watching the build progress. It all takes more time than you'd think, doesn't it?
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Steve, it does all take longer than you'd think. I guess I'm not the most patient person there is but I can't work any faster so I'll just have to finish it when I finish it. Work gets in the way a lot and my wife thinks I'm spending too much time in the shop as it is. I bet that's never happened to anybody else though...
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Time to update the trailer project. I have been working on it but haven't taken the time to update here. Since my last post, I have finished the decking, run the trailer wiring for lights, routed the propane line for the furnace, wired the walls for receptacles & 12V devices. I routed the gas line through the floor framing and all of the wiring & water line through the walls. I didn't want to drill the floor framing any more than I had to. I also tried to take care to make sure nothing would rub & chafe by wrapping the gas line with wiring loom & using armored cable for the 120V wiring and SO cord for the 12V wiring. I also deburred all of the holes I drilled.
Like any project, I started out with a written plan for what I wanted and a list for parts.
(http://imageshack.us/a/img703/7587/elecplumbplans.jpg) (http://imageshack.us/photo/my-images/703/elecplumbplans.jpg/)
I protected all of the light wiring in plastic loom as well as the propane line.
(http://imageshack.us/a/img854/5530/trailerwiring2.jpg) (http://imageshack.us/photo/my-images/854/trailerwiring2.jpg/)
(http://imageshack.us/a/img202/3536/trailerwiring.jpg) (http://imageshack.us/photo/my-images/202/trailerwiring.jpg/)
I deburred all the holes for wiring & plumbing.
(http://imageshack.us/a/img585/9601/wiringthroughstud.jpg) (http://imageshack.us/photo/my-images/585/wiringthroughstud.jpg/)
(http://imageshack.us/a/img15/7021/trailerwiring5.jpg) (http://imageshack.us/photo/my-images/15/trailerwiring5.jpg/)
Wiring-Plumbing is all in.
(http://imageshack.us/a/img29/2966/leftsidewiring.jpg) (http://imageshack.us/photo/my-images/29/leftsidewiring.jpg/)
(http://imageshack.us/a/img5/4181/leftsidewiring2.jpg) (http://imageshack.us/photo/my-images/5/leftsidewiring2.jpg/)
The gas line is routed through the floor. The floor will be insulated with foam and a skin will be put on the bottom to protect everything.
(http://imageshack.us/a/img715/1582/gasline2.jpg) (http://imageshack.us/photo/my-images/715/gasline2.jpg/)
(http://imageshack.us/a/img442/3821/gasline3.jpg) (http://imageshack.us/photo/my-images/442/gasline3.jpg/)
(http://imageshack.us/a/img19/3536/trailerwiring.jpg) (http://imageshack.us/photo/my-images/19/trailerwiring.jpg/)
I plan to have a switch at the front of the trailer for the water pump control and light plugs on the entry side of the trailer so I can plug in outside lights. There are also 120V outlets inside the trailer and outside that will run to a cord & plug. I've been waiting 2 weeks for the sheet-metal for the sides and top and I'm getting anxious to get started putting the skin on. Once the inside is skinned and the top is built, I will have it insulated. I've got a friend who sells the spray-in house insulation and he's going to have one of his crews spray it with left-over product from a house. Then the outside skin will be installed and attached, once everything I want to attach is installed, I'll remove the skin and have it painted or powder-coated. That's where I'm at for now.
I also put flat fender flares on my Jeep recently, I know some of you have them and I was needing extra clearance since my tires rubbed on some of the trails. That's quite a project, more time than I anticipated.
Before with my old fender flares.
(http://imageshack.us/a/img703/9761/passb4.jpg) (http://imageshack.us/photo/my-images/703/passb4.jpg/)
After with the flat flares. I did pick up several inches of clearance.
(http://imageshack.us/a/img822/9738/passafter.jpg) (http://imageshack.us/photo/my-images/822/passafter.jpg/)
(http://imageshack.us/a/img22/369/rrfenderb4.jpg) (http://imageshack.us/photo/my-images/22/rrfenderb4.jpg/)
(http://imageshack.us/a/img163/6861/20130316162817.jpg) (http://imageshack.us/photo/my-images/163/20130316162817.jpg/)
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The progress is looking great. Fabrication is so appealing to me, I could build anything out of wood but not to much experience with metal. Hope to get welder and tube bender sooner than later. Any you recommend that more entry to mid level? I will keep tuned in, good luck with the rest of your build.
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Time again to update the camp trailer project. I've not been getting much time to work on it as this is the busy time of year for my line of work. But I have lined the inside of the trailer with aluminum sheet metal, received the (sex bolts) for attaching the outside skin to the inside skin, mounted electrical boxes in the wall, broken the sheetmetal for the outside, and very recently, I finally got it spray foam insulated. Bottom and sides anyway. I'll have to get the top done when I have it fully fabricated. Pics below. Cousin Vinny, I don't really have any recommendations on equipment, I would say stalk CL or something to find something cheap to get started and then upgrade as you understand it more. Sorry I don't have better advice.
Here are shots of the liner panels. They have temporary bolts in them now, the sex bolts have to be driven in from the outside and I won't install them until the outer skin is ready to install or I'd have to drive them back out. The look is really clean though.
(http://imageshack.us/a/img13/4056/innerpanels2.jpg)
(http://imageshack.us/a/img823/1135/innerpanels.jpg)
Here is the sex bolt I'm using, it has a counter-sunk head for the inside and the outside looks like a rivet but is really a rounded head with a splined shaft that gets driven in.
(https://imageshack.us/a/img27/3231/sexbolt.jpg)
(https://imageshack.us/a/img841/7922/sexbolt2.jpg)
Here is a shot of the inside/outside of the bolts. They will be flush on the inside.
(https://imageshack.us/a/img580/5909/sexboltthroughstud.jpg)[/URL]
(https://imageshack.us/a/img28/6894/flushboltoninnerpanel.jpg)
While waiting for insulation, I started mocking up with conduit, what shape I wanted for the fenders. I plan to make them out of 1/4" aluminum treadplate but wanted a template to shape them to. I like the last image best...Opinions?
(https://imageshack.us/a/img850/5657/fendermockup.jpg)
(https://imageshack.us/a/img841/8721/fendermockup2.jpg)
(https://imageshack.us/a/img19/9225/fendermockup5.jpg)
Here's a shot of the trailer getting insulated. We sprayed the walls and tipped it up on end to spray the bottom.
(https://imageshack.us/a/img51/516/insulation4.jpg)
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No opinions on the fender angle or width, etc.???
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Your skill's are already way above any advise I could give you!, it's looking good!
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I agree I like the last mock up the best. Trailer is looking good!
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Just wanted to post up that I haven't abandoned the trailer project, this summer has just been busy as hell at work so no time. I have obtained the aluminum for the top, sides and fenders so I've just got to get time to break it and install it. Hopefully soon!
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Spent a couple of hours today back on the trailer. I'm way behind where I thought I would be. I've got to give up my day job.
Anyway, I do have the sides all ready to install (I have them sitting on the trailer now and I got the top broke & welded last week. Today I cut out the mitered corners on the sides, sat them on the trailer & drilled/cut holes for the wiring where it comes through the walls for receptacles. I also installed the tail lights. Here are a few pics of the progress.
Here's a picture from the front with all of the sides on.
(http://imageshack.com/a/img845/9382/nv6u.jpg)
Another picture from the rear corner with all of the skin on.
(http://imageshack.com/a/img827/5290/nf53.jpg)
Tail lights installed (not wired yet)
(http://imageshack.com/a/img20/1050/hylc.jpg)
Top sitting on the trailer. It fits just right which is good since I couldn't fix it if it didn't.
(http://imageshack.com/a/img534/7831/7fgh.jpg)
The next steps are to drill all the holes for the bolts through the outer skins, fabricate the fenders & drill mounting holes for them & any other holes I need to drill. Then it's off to get the skins powder-coated. The top & fenders are getting under-coated.
I'll try to get some more finished & posted this week if I can get some time...
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I've been wondering how your project was going! You need to pick up the pace - camping season is right around the corner (in spite of the fact that it was 3* last Monday morning)!
Looking forward to watching your progress!
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I'm determined not to spend another camping season in a tent on the ground. I'm too old for that.
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This week I got the fenders built & cut out both doors. (AC door & entry door) I also got the entry door built & temporarily installed it to check fit. I purchased some cool hinges for it that I wanted to test. I'm also building a sliding tray for the A/C unit to slide out when in use and slide in for travel. I got a pretty cool latch for the door also that looks like a chrome jeep handle.
Fenders fabbed up. We'll cut off the flat portion once they're on and I see how long I can leave it. The fenders are 1/4" aluminum tread-plate so they're plenty solid enough to sit on or use as a table. They'll be mounted with bolts all the way through the frame. I think they ended up a little wider than I like so we'll see how it looks once they're installed.
(http://imagizer.imageshack.us/v2/xq90/845/zjuj.jpg) (https://imageshack.com/i/nhzjujj)
I think I will flip the fenders around and have the flat portion at the back. It might get in the way of the doors on the front.
(http://imagizer.imageshack.us/v2/xq90/841/n7m7.jpg) (https://imageshack.com/i/ndn7m7j)
(http://imagizer.imageshack.us/v2/xq90/842/dq61.jpg) (https://imageshack.com/i/nedq61j)
Door installed and it fits pretty well. I've still got to install stops for it to seal against.
(http://imagizer.imageshack.us/v2/xq90/841/fzrn.jpg) (https://imageshack.com/i/ndfzrnj)
The door latch will lock so I can store stuff in the trailer and have it be reasonably secure. I've also got locks for the top.
(http://imagizer.imageshack.us/v2/xq90/834/zcyf.jpg) (https://imageshack.com/i/n6zcyfj)
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Looking good! Fabbin' is fun, but it sure does take a lot of time!
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Got a little more work done on the trailer this week. We worked on putting a trim piece around the top of the trailer. Basically we broke some sheetmetal into channel and fit it around the top just to trim out everything. We also finished the door and have the latch installed. We got the framing inside the lid, attached the piano hinge and actually attached the lid to the trailer. It's starting to get pretty close. We also cut out the opening for the A/C and installed a shelf on drawer slides so it can be pulled out.
Here's the finished door. We just have to add a door stop for it to seal against.
(http://imagizer.imageshack.us/v2/xq90/835/mwji.jpg) (https://imageshack.com/i/n7mwjij)
Here's a pic of the lid hinge and you can see the A/C unit in the opening. We're working on a door for it next.
(http://imagizer.imageshack.us/v2/xq90/838/d0g6.jpg) (https://imageshack.com/i/nad0g6j)
Here's what the lid looks like open. This will become a queen-sized bed.
(http://imagizer.imageshack.us/v2/xq90/836/va4d.jpg) (https://imageshack.com/i/n8va4dj)
Next up we'll install the door for the A/C, finish the fenders and attach them, then disassemble everything so the sides can be powder-coated.
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I've been working on the trailer, just haven't taken time to post. I'll summarize what I've gotten done, then post pics with some comments.
We built mounts for the rack system that will fit on the top. I want to be able to quickly remove them so we made brackets we can mount a standard rack to.
We had to fab supports for the lid. The factory trailers use a square tube-in-tube with holes but that doesn't give a finite adjustment so we took a standard trailer stabilizer and lengthened it to work for the lid. I ended up with about 10" of adjustment (up & down) in case the ground isn't level.
We had to come up with mounts inside the lid for the bimini poles that will support the tent.
We had to install snaps on the trailer for the tent to attach to. I even have to install snaps on the tent itself, it came with some on it but not all the way around.
We cut through the back of trailer for the furnace intake/exhaust.
We got the A/C door built.
We installed a water fill port in the side of the trailer. I purchased an RV fill spout to install.
After getting everything attached and all the holes cut we thought needed to be cut, I took the exterior panels to be powder-coated. I tried to match my Jeep color and it came in pretty close but a couple shades lighter. I also had the top rhino-lined, it turned out very nice. (Thanks to Shane at Safari)
We now have the powder-coated sides all installed with the sex-bolts (also powder-coated to match) and they look very nice.
I coated the top trim piece with black bed-liner.
Lastly, we're modifying the fenders, I didn't like how they looked so we're trimming them up.
Kayak rack mount
(http://imagizer.imageshack.us/v2/xq90/841/a0sim.jpg) (https://imageshack.com/i/nda0simj)
(http://imagizer.imageshack.us/v2/xq90/829/kcsa.jpg) (https://imageshack.com/i/n1kcsaj)
Finished rack
(http://imagizer.imageshack.us/v2/xq90/823/3uz6.jpg) (https://imageshack.com/i/mv3uz6j)
Stabilizer jack out of the box, before we modified it
(http://imagizer.imageshack.us/v2/xq90/819/qkm2.jpg) (https://imageshack.com/i/mrqkm2j)
Cut it in half
(http://imagizer.imageshack.us/v2/xq90/856/slsa.jpg) (https://imageshack.com/i/nsslsaj)
Make it longer
(http://imagizer.imageshack.us/v2/xq90/841/ti96d.jpg) (https://imageshack.com/i/ndti96dj)
Paint it to match the top of the camper
(http://imagizer.imageshack.us/v2/xq90/850/tqny.jpg) (https://imageshack.com/i/nmtqnyj)
Furnace exhaust/intake plate
(http://imagizer.imageshack.us/v2/xq90/840/2usf.jpg) (https://imageshack.com/i/nc2usfj)
Water fill port
(http://imagizer.imageshack.us/v2/xq90/855/57kz.jpg) (https://imageshack.com/i/nr57kzj)
Making the A/C door
(http://imagizer.imageshack.us/v2/xq90/819/xxoy.jpg) (https://imageshack.com/i/mrxxoyj)
A/C Slide system so it can be pulled out to work properly
(http://imagizer.imageshack.us/v2/xq90/842/fsymo.jpg) (https://imageshack.com/i/nefsymoj)
Finished A/C door
(http://imagizer.imageshack.us/v2/xq90/843/eiq0l.jpg) (https://imageshack.com/i/nfeiq0lj)
(http://imagizer.imageshack.us/v2/xq90/842/hhycr.jpg) (https://imageshack.com/i/nehhycrj)
Off to the Powder coater
(http://imagizer.imageshack.us/v2/xq90/818/tka8.jpg) (https://imageshack.com/i/mqtka8j)
While waiting, we sprayed some trim pieces
(http://imagizer.imageshack.us/v2/xq90/853/a6eg.jpg) (https://imageshack.com/i/npa6egj)
Got it all back from powder coating, it turned out lighter than I wanted but still looks good.
(http://imagizer.imageshack.us/v2/xq90/849/hhoo.jpg) (https://imageshack.com/i/nlhhooj)
Driver's side finished with fill-port & coated sex-bolts. I like how it turned out.
(http://imagizer.imageshack.us/v2/xq90/822/ig56x.jpg) (https://imageshack.com/i/muig56xj)
(http://imagizer.imageshack.us/v2/xq90/829/gv2t.jpg) (https://imageshack.com/i/n1gv2tj)
We coated the lid hinge as well and used machine screws and tapped the holes so it can be removed need be.
(http://imagizer.imageshack.us/v2/xq90/853/pn2k.jpg) (https://imageshack.com/i/nppn2kj)
Fenders after we modified them.
(http://imagizer.imageshack.us/v2/xq90/840/kdhj.jpg) (https://imageshack.com/i/nckdhjj)
(http://imagizer.imageshack.us/v2/xq90/837/yy3o.jpg) (https://imageshack.com/i/n9yy3oj)
Taillights installed & wired
(http://imagizer.imageshack.us/v2/xq90/853/30ex.jpg) (https://imageshack.com/i/np30exj)
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Today I worked some more and we got the top on and got the kayak rack and bed supports installed.
Here are a couple of pictures with everything on and ready to set up the tent. I still have to make the poles for the tent and finish the bench seat but it's getting close finally.
(http://imagizer.imageshack.us/v2/xq90/843/aa72s.jpg) (https://imageshack.com/i/nfaa72sj)
(http://imagizer.imageshack.us/v2/xq90/840/kryc.jpg) (https://imageshack.com/i/nckrycj)
So...any feedback on any of the pics? I'm questioning the fenders the most. They should be simple but have not proven to be so.
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Wow! That is a lot of work. I sure hope you get as many hours of camping with it as you have put into building it! What don't you like about the fenders?
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It has been a lot of work. I will probably take years to get as much camping in it as I have building it but the building has been fun too. As to the fenders, I think I made them too wide. I also initially had a flat spot at the front to use as a step or storage but it interfered with the doors so I cut it off. Then we rounded the outside corners and I like that a little better but we'll see...These crazy things have been cut & welded so much. Plus I made them out of 1/4" aluminum treadplate so they would hold up if I bumped them into something so they're hard to work with.
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I have the fenders mounted on the trailer and would like some feedback. Here are several shots from different angles. I still think they're too wide but...
Other than that, I like the shape and they should be stout enough to take a hit or two without just folding up. I took all the pictures of the driver's side since I don't have a lot of room on the other side but they're the same.
(http://imagizer.imageshack.us/v2/xq90/829/u780.jpg) (https://imageshack.com/i/n1u780j)
(http://imagizer.imageshack.us/v2/xq90/843/exir2.jpg) (https://imageshack.com/i/nfexir2j)
(http://imagizer.imageshack.us/v2/xq90/823/txgg.jpg) (https://imageshack.com/i/mvtxggj)
(http://imagizer.imageshack.us/v2/xq90/849/ex9t.jpg) (https://imageshack.com/i/nlex9tj)
Next I'll get the gaskets installed around the doors & lid & finish with the snaps for the tent. Last thing is to build the bench seat inside, then it's ready to camp in. This fall, I'll get the kitchen portion built that goes on the front. I've been doing some research on that and have some sketches done but if anyone has any cool ideas, I'm open.
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I think the fenders look great.
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I got the gaskets for the top installed this weekend. I'll follow up with a picture later. I spent quite a bit of time looking for the right gasket. I finally settled on a 2 inch wide double hump gasket that gives me 2 sealing points. Going to try to finish up the tent fasteners this week.
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Here are 3 shots of the gasket. I'm hoping to get a pretty good seal to keep out moisture, dust, etc. I'm pretty happy with the gasket but we'll see how it holds up. Also, it is self-adhesive so I'm concerned when it gets hot that it might come loose. Just have to try it & see.
(http://imagizer.imageshack.us/v2/xq90/856/32cw.jpg) (https://imageshack.com/i/ns32cwj)
(http://imagizer.imageshack.us/v2/xq90/856/tzqt.jpg) (https://imageshack.com/i/nstzqtj)
(http://imagizer.imageshack.us/v2/xq90/849/toem.jpg) (https://imageshack.com/i/nltoemj)
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I spent some time over the 3-day weekend working on the trailer. Basically I got all of the snaps installed in the tent and the other side of the snap installed on the trailer. I wish the tent had come with all of the snaps installed but such is life. I bought stainless steel snaps from Fastenal with a tool to rivet them in. Then we had to punch a hole in the tent fabric & assemble the snap, and drive it together with the tool. On the trailer side, we measured & marked out where the snaps were now located on the tent, center-punched the spots & drilled pilot holes before using an impact to drive in the male snap piece. These pieces came with screws in them. We also put a dab of clear silicone on each one to seal them up.
(http://imagizer.imageshack.us/v2/xq90/822/0m5f.jpg) (https://imageshack.com/i/mu0m5fj)
(http://imagizer.imageshack.us/v2/xq90/855/y6mh.jpg) (https://imageshack.com/i/nry6mhj)
And now the tent is completely snapped onto the trailer. Next to fabricate the poles that will support it. I'm going to work on that some this weekend also.
(http://imagizer.imageshack.us/v2/xq90/850/yimdg.jpg) (https://imageshack.com/i/nmyimdgj)
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The bimini poles are going to be made out of 3/4" emt. (Electrical Metallic Tubing or conduit) Straight away, the conduit is too short so rather than order in some other tubing that would be long enough (because that's too damn easy and makes too much sense), we decided to bend the poles in 2 pieces and weld them together. I didn't want to just butt weld them so we had to fashion a insert that would fit snug and give the joint some strength. More time...
Anyway, I did get one pole finished and installed to support the tent, I'm working on the other 2 poles now. Once they're done, the tent will be completed and ready to use. I still have several items before the trailer is ready to camp in though.
Here are some pictures of fabricating the poles. I used my trusty emt conduit bender to get them to the right shape.
(http://imagizer.imageshack.us/v2/xq90/849/uix19.jpg) (https://imageshack.com/i/nluix19j)
I used a 4" piece of 1/2" emt to make the insert for the joint. I cut it down the middle and split it apart so it would fit snug.
(http://imagizer.imageshack.us/v2/xq90/822/pae8.jpg) (https://imageshack.com/i/mupae8j)
(http://imagizer.imageshack.us/v2/xq90/849/odvf.jpg) (https://imageshack.com/i/nlodvfj)
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If I can get the lights hooked up in time, I might tow it out to the work day and get some ideas for finishing up a few items. Steve, can you send me your address or directions?
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I got the lights wired up this morning and tested them. Everything works fine. I installed small LED marker lights on the fenders as MO-DOT requires marker lights. When I built the fenders, I didn't think far enough ahead to install some wireway for this. Just one of many errors. So to route the wiring, I bought some automotive decal adhesive and glued the wiring to the inside of the fender and sprayed it with undercoat to protect it & mask it. It looks okay. A channel welded in would have been much better but since I've already coated the fenders, I didn't want to go back & weld on them. I like the Jeep-style LED taillights though, they worked out well.
(http://imagizer.imageshack.us/v2/xq90/841/5tinj.jpg) (https://imageshack.com/i/nd5tinjj)
And marker lights. They're surprisingly bright.
(http://imagizer.imageshack.us/v2/xq90/850/fmgn.jpg) (https://imageshack.com/i/nmfmgnj)
(http://imagizer.imageshack.us/v2/xq90/850/hw74.jpg) (https://imageshack.com/i/nmhw74j)
Also, my neighbor who makes vinyl signs stopped by to B.S. because he's slow so he cranked out some Jeep logos for me and installed them. They look great!
(http://imagizer.imageshack.us/v2/xq90/849/luzj.jpg) (https://imageshack.com/i/nlluzjj)
(http://imagizer.imageshack.us/v2/xq90/850/v8nr.jpg) (https://imageshack.com/i/nmv8nrj)
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Kelly, any updates? (and thanks for the radiator info!).
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Steve, I have done some more but haven't posted up pics yet. I do have the first camping trip scheduled for the 12th of Sept. so it'll have to be ready by then. Been really busy at work with 100Deg days! I'll get some updates posted soon. Thanks for asking.
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I do have all of the support poles built now and the tent is actually finished! First we had to make brackets that we could weld to the support poles that would hinge down into the trailer when it's folded down. That took some finagling. It took me a couple of tries also to get the shape of the poles correct to match the profile of the tent. I bent the main supports out of 3/4" emt and the cross supports out of 1/2" emt. We put a 1/4" solid rod into the 1/2" conduit and welded it in so that it can slide into 1/4" holes drilled into the main supports. It turned out really nice and is actually very solid. I also got the A/C mounted on slide mounts and it's running. I still have to get the frame for the bench seat made and about a hundred little loose ends to clean up. Hopefully I'll make some good head-way on it next week.
Hinge brackets we made and welded to the support poles. They fold inside the box.
(http://imagizer.imageshack.us/v2/xq90/537/r6WUTh.jpg) (https://imageshack.com/i/exr6WUThj)
This is the 1/4" rod with some nuts we slid on to space it in the 1/2" conduit.
(http://imagizer.imageshack.us/v2/xq90/745/1vyxda.jpg) (https://imageshack.com/i/kp1vyxdaj)
Here's a shot of the tent set up with the A/C unit installed.
(http://imagizer.imageshack.us/v2/xq90/673/fdFjSe.jpg) (https://imageshack.com/i/ipfdFjSej)
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Here's a shot from the back of the trailer.
(http://imagizer.imageshack.us/v2/xq90/909/jwR4lw.jpg) (https://imageshack.com/i/p9jwR4lwj)
Here's a shot of the inside. It is actually pretty roomy for such a small trailer. Queen size bed. Room to stand up.
(http://imagizer.imageshack.us/v2/xq90/908/rYpgQs.jpg) (https://imageshack.com/i/p8rYpgQsj)
I ran the A/C for about an hour with it sitting inside my hot shop and was able to bring the temp inside the tent to about 72 degrees.
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So to wrap it up (other than the kitchen box), I've got the cushions for the bench seat ordered, the materials for the frame of the seat will be here monday and I should be able to finish trimming out the electrical devices then also. Should be able to camp by next weekend. Which is good since I have a spot reserved at Roaring River next weekend.
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Verrry Nice! I was hoping to see it this weekend at SMORR!
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I am camping this weekend, unfortunately I won't be at SMORR. I will be at Roaring River helping girl scouts learn to fish. The things we do for our kids huh?
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You're a good man! Have fun!
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Well, I got the trailer out for the first time and it went pretty well. We didn't have any big wind or rain so I couldn't see how it worked in that but overall I was pleased with it. With the wheel on the jack and as light as it is, it rolls around very easily. Unhitching it just requires putting the jack down and taking some pressure off the hitch. Then just roll it backwards and move it where you want it. To set it up, I just put the legs in position, swing the top over (not easy since it's too heavy) and set up the tent portion. I did time it to see how long it takes. I can set it up in just under 10 mins. and it took me 7 mins. to take it back down. I'm going to work on the bench seat & furnace this week to try and get them finished, I might want the furnace for hunting season. Here are a couple of pics of the trailer set up at Roaring River campground.
(http://imagizer.imageshack.us/v2/xq90/746/xV2zXo.jpg) (https://imageshack.com/i/kqxV2zXoj)
(http://imagizer.imageshack.us/v2/xq90/538/RUSxC9.jpg) (https://imageshack.com/i/eyRUSxC9j)
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Turned out great Kelly, really looks nice!
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Thanks Steve. Still got some things to finish up but I'm pretty satisfied how it's turned out. Hope to finish up the 12V system this week, I picked up a converter the other day. I've got the design figured out, just have to get some time to wire it up and install everything. I'm also going to try to finish the frame for the bench seat this week. I'll post up some pictures later. After the converter (which runs the furnace) and the bench seat, it'll be pretty well finished except for the kitchen. Here's a picture of what I'm thinking on that...
(http://imagizer.imageshack.us/v2/xq90/674/ilBd5i.jpg) (https://imageshack.com/i/iqilBd5ij)
Cook stove, sink & some storage in a pull-out drawer with some drop-down legs.
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I had been needing to finish off the outside receptacle and 12VDC receptacle. I wanted them to have weather-proof covers and was trying to figure out how to get them in one nice package. I ended up getting a double receptacle cover and converting one of them for the 12VDC. I used a modular coax device and removed the coax connector and drilled it out for the new receptacle. Then painted it black to match the trailer. It turned out pretty good.
(http://imagizer.imageshack.us/v2/xq90/909/JoSsyT.jpg) (https://imageshack.com/i/p9JoSsyTj)
(http://imagizer.imageshack.us/v2/xq90/911/m7y144.jpg) (https://imageshack.com/i/pbm7y144j)
(http://imagizer.imageshack.us/v2/xq90/911/82dyYw.jpg) (https://imageshack.com/i/pb82dyYwj)
(http://imagizer.imageshack.us/v2/xq90/905/06KylI.jpg) (https://imageshack.com/i/p506KylIj)
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I've been doing some work on the bench seat frame also. I wanted to use some futon brackets that would fold out but they sat the front end up too high due to the angle they use. Instead we just made a frame using a hinge and fabricated a latching system so it wouldn't move around and to have support when it's folded down for a bed.
(http://imagizer.imageshack.us/v2/xq90/742/1VWMVE.jpg) (https://imageshack.com/i/km1VWMVEj)
Bottom frame
(http://imagizer.imageshack.us/v2/xq90/661/5wZtDe.jpg) (https://imageshack.com/i/id5wZtDej)
Bottom & back frames
(http://imagizer.imageshack.us/v2/xq90/537/RchIEd.jpg) (https://imageshack.com/i/exRchIEdj)
(http://imagizer.imageshack.us/v2/xq90/912/Dp7QTz.jpg) (https://imageshack.com/i/pcDp7QTzj)
This is the latching mechanism we built. It springs out and we routed a cable to pull it in routed to the front of the frame and attached to a lawn mower pull handle.
(http://imagizer.imageshack.us/v2/xq90/538/deZSNE.jpg) (https://imageshack.com/i/eydeZSNEj)
Finished Frame
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I also got the frame built over the A/C so I can sit on it without damaging the unit. I covered it in expanded aluminum so the air could flow freely.
(http://imagizer.imageshack.us/v2/xq90/540/CO8w2p.jpg) (https://imageshack.com/i/f0CO8w2pj)
Seems to work fine. The inside is basically done. Waiting for the cushions to be done. I'll finish the DC electrical system this week so the battery can be charged and the furnace can run, after that I'm down to building the kitchen. I'm going to temporarily mount a toolbox and battery box to the front until the kitchen is finished so I have some more storage.
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The trailer is finished. Only took me about 18 months...which is about 15 months longer than it should have. Oh well. I'm still going to build the slide-out kitchen this winter but will camp in it as-is for now. I've got the seat completed inside, got the furnace started and running and finished the DC charging & power system. We installed a bulkhead under the bench-seat to make that into storage and installed the front on the furnace at the bulkhead. I installed a thermostat for the furnace right next to the bed so I can roll over and turn it on in the mornings. I also got the storage box & battery box put on the front of the trailer for now. They'll be relocated later when the kitchen is finished. The battery will go on the tongue and the storage box will come off. We also got a bracket to mount the propane tank to the front. It turned out nice. The propane tank will stay where it is and the kitchen box will go around it to hide it. I also bought a horse stall mat and put on the floor. We cut it to fit. This has been a real learning experience, so if anyone else has a hankering to build a camper, hit me up and I'll give drawings, advice & whatever else help I can. Hopefully some of my mistakes can be avoided. Here are some pictures of the finished bench seat, the furnace cover, and the equipment on the front of the trailer.
(http://imagizer.imageshack.us/v2/xq90/911/SJL1h5.jpg) (https://imageshack.com/i/pbSJL1h5j)
(http://imagizer.imageshack.us/v2/xq90/673/NbwBIV.jpg) (https://imageshack.com/i/ipNbwBIVj)
(http://imagizer.imageshack.us/v2/xq90/674/xekmIJ.jpg) (https://imageshack.com/i/iqxekmIJj)
(http://imagizer.imageshack.us/v2/xq90/911/TLdd32.jpg) (https://imageshack.com/i/pbTLdd32j)
(http://imagizer.imageshack.us/v2/xq90/540/jxCV8l.jpg) (https://imageshack.com/i/f0jxCV8lj)
(http://imagizer.imageshack.us/v2/xq90/743/dQYkhr.jpg) (https://imageshack.com/i/kndQYkhrj)
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I forgot to mention we also got some lights wired. I didn't take any pics yet but I'll post some up later. I bought a couple of RV snap-on lights from a camper store that are made for pop-up campers. We fished a wire up through the center tent support pole from the power under the bench seat. Then I got a couple of 1/4" audio jacks from Radio Shack and soldered them to the wire so the lights can plug in. The one for the bed even has a little fan on it. They just snap onto the poles over the bed & one over the table area.
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Nice job Kelly! :41:
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Here are a couple more pictures of the trailer with some final things added. I did use the kayak rack this weekend as we went to the Current river to camp and fish. It worked well and had no problem fitting 2 kayaks on top. I was also able to fit my daughter's bike on the back which was a bonus. The camping went pretty well, I do have some adjustments to make to the trailer. The tent hoop I made for the bed is too wide to fit in the box when I fold the tent up. I had been putting it in at an angle but with the mattress & seat cushions & tent all folded in, it doesn't fit very well. I'm going to shorten it up this week and make new socket holes in the bed for it that are 3 inches narrower. I don't think it will affect the fit of the tent. The furnace worked well as it was pretty cold Saturday morning. I left it off all night but it was nice to use it to warm up the camper first thing in the morning. The lights also worked out pretty well. I can plug them in and they have brackets that hook to the tent poles. I also think I need to get the stabilizers I bought installed to help keep it in place. With the big tires, it wants to roll around too easily.
I got the mattress put in and temporarily put some seat cushions off my outdoor rocker in until mine get finished next month. It slept a lot better than being on the ground!
(http://imagizer.imageshack.us/v2/xq90/661/r2ds8D.jpg) (https://imageshack.com/i/idr2ds8Dj)
Here's a shot of the kayaks on top behind my truck. I used the truck for this trip since I haven't put my hard-top on yet and I wasn't sure about the weather. I know it's a stinkin' Toyota but it gets me around.
(http://imagizer.imageshack.us/v2/xq90/911/VJezdm.jpg) (https://imageshack.com/i/pbVJezdmj)
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Really really turned out great, and thanks for the write up and pictures Kelly
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The upholsterer called yesterday to tell me my seat cushions were done. I pulled the trailer out and set it up in their parking lot so I could put the cushions in and make sure they fit. The fit was great. They did a really good job. The one hitch was the foam they ordered for the cushions came in as 6" instead of the 5" we ordered. They called me ahead of time about it but I didn't want to wait for more foam to come in so we went ahead. It works fine except the bottom cushion sits right up against my furnace T-stat. I'll have to move the T-stat up an inch or so.
They embroidered the Jeep logo into the back cushion for me.
(http://imagizer.imageshack.us/v2/xq90/537/AXoye7.jpg) (https://imageshack.com/i/exAXoye7j)
(http://imagizer.imageshack.us/v2/xq90/673/XOqTuu.jpg) (https://imageshack.com/i/ipXOqTuuj)
Now everything is complete with the inside of the trailer. Still working on the camp kitchen for the front. Should start making some progress on it soon. I have changed what I wanted at least a dozen times but the overall concept is still the same. I'm going to do a pull-out cabinet of sorts that will have a built-in stove, sink and as much storage and work-space as I can squeeze into it. I'll try to post some concept drawings up soon and hopefully some in-progress pictures also.
Thanks for the compliments!
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Here's my drawing. I'm going to build an aluminum frame with shelves and a lowered space for the stove. The sink will be cut into the top. I was going to do drawers but changed my mind since I was afraid I wouldn't be able to keep them tight enough to seal out dirt & dust. Instead I'm going to make shelves with dividers and slide in plastic bins with lids on top that will seal. It'll also allow the bins to be pulled out either side for convenience. The end plate which will be the outside panel, will fold up to be more work-space. I had originally planned to do a drawer on slides but now I'm thinking it'll have legs and pull out to be free-standing. That'll allow me to move it around a bit. I'll still have to be close enough for the water line & propane lines to reach but should have some flexibility there. So, any fresh ideas?
(http://imagizer.imageshack.us/v2/xq90/901/5IC77Z.jpg) (https://imageshack.com/i/p15IC77Zj)
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Got started on the camp kitchen for the trailer this week. I've finally decided on how I want it to look. I put together a 3D drawing with dimensions and came up with a materials list. Picked up the material this week ($250). All aluminum tubing & angle. I got the main frame put together, taking quite a bit of time to make sure it was square all around. It's kind of a pain to keep it square as you weld it, the heat causes it to pull different directions. A jig would work better but it's not worth fabricating a jig to make one item. I'm going to try to get more of it put together while I'm off for a few days around the holidays. Hopefully it'll be pretty well done by the end of the year. Here's some pictures of what I've done so far.
The final drawing with dimensions.
(http://imagizer.imageshack.us/v2/xq90/540/0clx6X.jpg) (https://imageshack.com/i/f00clx6Xj)
The pile of aluminum stock after unloading.
(http://imagizer.imageshack.us/v2/xq90/912/Q4yQqz.jpg) (https://imageshack.com/i/pcQ4yQqzj)
We spent about an hour cutting all the pieces.
(http://imagizer.imageshack.us/v2/xq90/661/K5Nyea.jpg) (https://imageshack.com/i/idK5Nyeaj)
Marked the pieces by measurement to help avoid screwing up. (We will anyway)
(http://imagizer.imageshack.us/v2/xq90/910/A0tFZ1.jpg) (https://imageshack.com/i/paA0tFZ1j)
Welding up the basic frame.
(http://imagizer.imageshack.us/v2/xq90/673/SiTQmA.jpg) (https://imageshack.com/i/ipSiTQmAj)
We're not welding the inside joints where the angle goes so the angle can sit tight in the corners but we're welding the joints where the angle meets the tubing. It's shaping up to be much stronger than I thought it would. I might cut down on some of the bracing I had drawn in to save on weight.
(http://imagizer.imageshack.us/v2/xq90/673/KznUfF.jpg) (https://imageshack.com/i/ipKznUfFj)
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Spent some more time on the kitchen project today. Really more of an aluminum camp box at this point. With all of the pieces pre-cut, it is going together pretty quickly. I did decide to eliminate some of the vertical supports since after getting the main frame put together, it's very solid. I did keep supports under the stove since it could have heavy pots on it. The plastic tubs I think are going to work well. I might have to fab some sort of dividers for a couple of them to break up the space or use smaller plastic tubs inside of these. The space under the worktable on the left will be storage for cutting boards and a griddle for the stove. I've decided to nix the sink and use wash tubs instead. I think it'll help conserve water and I can dump them without worrying about a drain on the sink. I'm still going to have a water spout at the edge of the trailer that I can use for water supply from the storage tank but no sink. I can add it later if I change my mind. I'm going to plumb the propane from the stove over to the edge of the kitchen frame and use a hose and quick-connect fittings to connect to the trailer propane supply. I'm also thinking of building a small stand with some LED lights for the work area. Has anyone found any good LED camper lights?
Here are a few pictures I took of the project as it moves along.
(http://imagizer.imageshack.us/v2/xq90/661/KnaYAD.jpg) (https://imageshack.com/i/idKnaYADj)
(http://imagizer.imageshack.us/v2/xq90/673/D0fPA7.jpg) (https://imageshack.com/i/ipD0fPA7j)
(http://imagizer.imageshack.us/v2/xq90/540/PtTdaW.jpg) (https://imageshack.com/i/f0PtTdaWj)
(http://imagizer.imageshack.us/v2/xq90/540/fSscvk.jpg) (https://imageshack.com/i/f0fSscvkj)
(http://imagizer.imageshack.us/v2/xq90/661/taBTpx.jpg) (https://imageshack.com/i/idtaBTpxj)
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I worked on the kitchen a bit more this weekend. Mainly added some expanded aluminum to the shelf under the counter so I can store the griddle & cutting boards in there. Also cleaned up some of the welds & ground some of the joints down. Finally I worked on the legs that will fold out to support the unit since I decided to make it free-standing. I went through several iterations from drop down inside the vertical supports to something that would just stick on the bottom and finally settled on legs that will swing down from the ends and fold-up under the unit. There will be a fold-down support to spread the legs apart wider than the box for more stability. We drilled a hole in the frame and slid a 1/4" rod through the entire box. There will be 1X1 angle threaded on the rod to allow it to swing. We'll weld a stop in front of the leg to support it past vertical once it's folded out. The folding support will force the 2 legs apart wider than the box. (That's the idea anyway) Here are a couple of pictures of where I got with it. Still have to make the support. Once it's all installed and working like I want, I'll weld up the holes so the rod won't be able to work its way out.
(http://imagizer.imageshack.us/v2/xq90/537/jVZRDD.jpg) (https://imageshack.com/i/exjVZRDDj)
(http://imagizer.imageshack.us/v2/xq90/908/CZ78pO.jpg) (https://imageshack.com/i/p8CZ78pOj)
(http://imagizer.imageshack.us/v2/xq90/537/Oca4ls.jpg) (https://imageshack.com/i/exOca4lsj)
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Well, like most everything I do, sometimes it doesn't work out like I think it should. After too much thought, work & rework, the leg design was a flop. It just wasn't stable enough. The attachment from the leg to the box wasn't solid enough using the rod. So, we scrapped that and have gone a different route. Still planning to use angle for the legs but they will be attached to the box with a sex bolt that we welded to the box and ground flush, leaving just a threaded insert. We had it stick through enough to come through the leg also so when we tighten the screw, we still have a leg that can swing open & closed. I bought a couple of locking arms for the fold-up table so we will use those also on the legs to lock them in position. That in itself has turned into a project. The locking arms aren't even length on either side of the pivot point so the angle of the arm when extended isn't 45 degrees. They came with measurements from each end to use but since they were to be on a table and our box measurements don't match up, we just had to play with them to get them to work correctly. It's amazing how much a very small movement in the attachment point changes the angle and function of the arm. I had figured the angles and measurements and we put it in only to find it wouldn't fold properly. In fact, it was hung up several inches from closing. After adjusting and moving it to find where it would work properly, we ended up 3/16" from our original starting point but that 3/16" made a huge difference. Here are some pictures of the trial/error process. Still have to weld in some attachment points and attach the arms to the legs permanently.
The original failed plan to have a spreader bar type setup. We couldn't get a solid enough attachment at the top.
(http://imagizer.imageshack.us/v2/xq90/673/SmAJVD.jpg) (https://imageshack.com/i/ipSmAJVDj)
(http://imagizer.imageshack.us/v2/xq90/537/rLC7Ly.jpg) (https://imageshack.com/i/exrLC7Lyj)
The locking arm setup. I think this will work much better.
(http://imagizer.imageshack.us/v2/xq90/909/84GPCw.jpg) (https://imageshack.com/i/p984GPCwj)
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I finally got one side of the legs finished and working like I want. I used the folding bracket and cross-braced from one leg to the other. Took some finagling but it works pretty well. I put nylon washers between the legs and the frame of the kitchen so the aluminum won't gald over time. I riveted the bracket into place and will probably use some loc-tite on the screws that hold the legs to the frame. We welded the sex bolt to the frame and ground it back smooth to keep from having anything stick out. Since the sex bolt receivers are aluminum, it covers perfectly and you just end up with a threaded insert on the inside.
(http://imagizer.imageshack.us/v2/xq90/538/GFdZEG.jpg) (https://imageshack.com/i/eyGFdZEGj)
(http://imagizer.imageshack.us/v2/xq90/540/tS65qY.jpg) (https://imageshack.com/i/f0tS65qYj)
I riveted the bracket to the leg and ground the rivet smooth.
(http://imagizer.imageshack.us/v2/xq90/913/l5DQhA.jpg) (https://imageshack.com/i/pdl5DQhAj)
(http://imagizer.imageshack.us/v2/xq90/674/NI9wSr.jpg) (https://imageshack.com/i/iqNI9wSrj)
Here's a picture of the leg system folded down. It needed to fold completely inside the frame so it can slide into the compartment I'm going to build on the front of the trailer. I didn't make the kitchen with really any spare room in the compartment. I'll have less than 1/2" to maneuver it.
(http://imagizer.imageshack.us/v2/xq90/674/9l7aK0.jpg) (https://imageshack.com/i/iq9l7aK0j)
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I have both sets of legs finished and got the prep top made. It's stainless so it added several pounds. It's basically finished except for the doors for the end of the doghouse, one of which will be an additional prep area that folds up.
Both sets of legs ready to go. It's pretty stable.
(http://imagizer.imageshack.us/v2/xq90/540/HDKGq4.jpg) (https://imageshack.com/i/f0HDKGq4j)
Here's a couple of shots with it set up and the prep area installed and the stove set on.
(http://imagizer.imageshack.us/v2/xq90/674/Actlwi.jpg) (https://imageshack.com/i/iqActlwij)
(http://imagizer.imageshack.us/v2/xq90/537/wKrUQX.jpg) (https://imageshack.com/i/exwKrUQXj)
(http://imagizer.imageshack.us/v2/xq90/674/Q7E6Wl.jpg) (https://imageshack.com/i/iqQ7E6Wlj)
Next up to build the "doghouse" that the kitchen will slide into. It's going to be 12ga. aluminum treadplate. I'm going to break the entire thing out of one piece to eliminate places for water leaks.
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I'm trying to get this project knocked out so I spent some time this afternoon working on the doghouse. First we had to take off all the temporary stuff I'd put on the front of the trailer for camping this fall. The box, battery & propane bottle. Only the propane will go back inside the box.
Here's the trailer stripped back down.
(http://imagizer.imageshack.us/v2/xq90/661/KBxAiL.jpg) (https://imageshack.com/i/idKBxAiLj)
And a couple of shots of the treadplate set in place. It will be screwed to the box and frame with butyl tape to seal it. The doors will be treadplate also. I'm trying to work out the gasket/seal setup now. I ordered some latches today that will latch the doors closed. The passenger side door will be attached to the kitchen and serve as the fold-up table. At least that's the plan.
(http://imagizer.imageshack.us/v2/xq90/674/P7tKSL.jpg) (https://imageshack.com/i/iqP7tKSLj)
(http://imagizer.imageshack.us/v2/xq90/674/qMwmS1.jpg) (https://imageshack.com/i/iqqMwmS1j)
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Okay, I haven't posted anything to this for awhile. I have finished most everything that I was working on and I'll put up some pictures and information on what I've done. I did build a fold-down shelf on the end of the camp kitchen. It works pretty slick. My original plan was for that to be the "door" for the end of the box so I wouldn't have to have another door. I don't think that's going to work because getting it to seal good was going to be unworkable. So, I built the shelf and I'm going to add 2 doors to either end to enclose the entire thing. I also bought an awning/screen room for the front of the tent. I had been planning this for awhile and it's part of the reason I changed my mind on having the kitchen slide out. If I couldn't move the kitchen, it would have been right against the screen. I set up a propane hose that I can roll up into the enclosure when the kitchen is stored and roll out to use the kitchen. It's got a quick-connect fitting and a shut-off valve. Seems to work pretty slick. It's long enough that I can move the kitchen around to find a good spot. I'm going to do the same thing with the water except it won't have a long hose, just enough to have a valve at the edge of the camper. I've gotten it out a couple of times this year already, I've been to the Buffalo River in Arkansas and camped this past week up at Pomme lake, just below the dam. We hauled kayaks along and did some fishing. The camper is working out exactly as I'd hoped.
The fold-down shelf, it provides more work space, or space to put another stove if need-be. I'm considering adding a burner right into the shelf and piping it to the existing stove.
(http://imagizer.imageshack.us/v2/1024x768q90/673/k872jo.jpg) (https://imageshack.com/i/ipk872joj)
(http://imagizer.imageshack.us/v2/1024x768q90/538/rGV10Y.jpg) (https://imageshack.com/i/eyrGV10Yj)
And folded down.
(http://imagizer.imageshack.us/v2/1024x768q90/540/85qt8C.jpg) (https://imageshack.com/i/f085qt8Cj)
All set up and ready for cooking.
(http://imagizer.imageshack.us/v2/1024x768q90/540/L5iWnd.jpg) (https://imageshack.com/i/f0L5iWndj)
Slid into the Dog-house. It's a very close fit, I probably should have allowed a little more wiggle room.
(http://imagizer.imageshack.us/v2/1024x768q90/913/MlKufx.jpg) (https://imageshack.com/i/pdMlKufxj)
Set up for camping at Pomme DeTerre Lake dam.
(http://imagizer.imageshack.us/v2/1024x768q90/538/PfFjqH.jpg) (https://imageshack.com/i/eyPfFjqHj)
(http://imagizer.imageshack.us/v2/1024x768q90/540/28sQXb.jpg) (https://imageshack.com/i/f028sQXbj)
My son paddling up by the discharge of the dam. The water rushing out of the dam there is awesome to see.
(http://imagizer.imageshack.us/v2/1024x768q90/538/DXmOZ2.jpg) (https://imageshack.com/i/eyDXmOZ2j)
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A couple more pictures and notes. I had been pondering for awhile how I wanted to set up the electrical system for protection. I've looked at some RV breaker panels and some fuse panels but really they're all overkill. I've only got 2 circuits in my camper, one AC and one DC and I didn't want to set up some big thing for this. I finally solved it by buying 2 in-line breakers and wiring them into the circuit, right where my power comes into the camper. I just mounted a small one-gang box, brought both wires (one from the battery and one from the power cord) into the box and put the breakers in series. I put a 20Amp on the DC circuit and a 30Amp on the AC circuit since that's what my wiring is rated for. I also mounted the battery to the tongue, I will build a small tray for it later when I've got some time, but for now it's in a boat battery box and strapped down.
What I've got left is to finish the 2 doors for the dog-house, I've got them cut, I just need to get them broke and put hinges on them. And last but not least, I've got the small RV pump I need to put under the seat so my fresh water tank can be of some use. I'll get both of those things done in the next week or so while I'm getting some use out of the camper.
(http://imagizer.imageshack.us/v2/1024x768q90/537/gdWuP9.jpg) (https://imageshack.com/i/exgdWuP9j)
(http://imagizer.imageshack.us/v2/1024x768q90/538/rgTB0L.jpg) (https://imageshack.com/i/eyrgTB0Lj)
(http://imagizer.imageshack.us/v2/1024x768q90/633/C8PyC9.jpg) (https://imageshack.com/i/hlC8PyC9j)
2 Kayaks fit on the top of the trailer almost perfectly.
(http://imagizer.imageshack.us/v2/1024x768q90/673/7l2RgH.jpg) (https://imageshack.com/i/ip7l2RgHj)
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Guys,
I'm considering building another trailer. I'm looking for input from anyone that has read through my build thread. If there's anything you would do differently or thought could have been better, sound off. There are at least a few things that I want to do differently.
- I want to get the weight for the entire unit down under 1,000 lbs
- I want to get it balanced better. Given the location of the door, the axle location is too far back, giving me quite a bit of tongue weight. It pulls great, but it's tough to maneuver by hand.
- The weight of the lid is too heavy. It works fine for me, but I don't believe my wife or a small person could swing it open by themselves.
These are the major items I want to correct in the next version. (2.0)
Otherwise, I've been very happy with the finished product, I've camped in it probably 20-30 nights now and it works great. Set-up is about 15mins. Same for take-down. It seals up tight, I've not had any dirt, bugs or moisture get into the unit while it is closed up.
So, any suggestions? Also, if you've seen any cool ideas on other trailers, I'm always looking at them but would welcome any ideas. I like the teardrops, but don't like that you can't stand up in them or take off your dirty boots without getting into your bed, unless you do it outside.