[Jord]

Well im still waiting for my new jimny, and getting pretty impatient too, but while I'm impatiently waiting I picked up a really cheap trailer.

The trailer is actually in fairly good condition considering the price I payed, but that isn't going to stop me from hacking it up and making it into a lightweight semi-offroad camper.

The plan is to remove the tray/box from the chassis and build a custom tray/box out of SHS and 1.6mm sheet to try keep it as light as possible (currently it is made from 3/ 3.5mm steel)which will incorporate compartments for batteries/watertanks/kitchen etc , I will also make a custom axle to match the zooks track, aswell as putting in lighter weight leaf packs (or just remove some leafs)oh and will be getting toyota 6 stud wheel hubs on it (unless i can find a suzuki 5stud hub)

The trailer seemed to tow pretty well behind the van today, but depending on how it goes with the narrower track I might extend the drawbar also.

any-who, this wil be a little build thread, even though I will be trashing the tray shortly, I couldn't stand looking at the mud guard that was rusted out so I made up a little patch today.










I hope to get a bit of work started over this weekend on the tray and axles

Jordan

[sideways]

If you're after Suzuki hubs, last time I was in supercheap they had f100 (same stud pattern) hubs. any trailer supplier should have them too.

[abclarke]

sideways wrote:

If you're after Suzuki hubs, last time I was in supercheap they had f100 (same stud pattern) hubs. any trailer supplier should have them too.

Really? stupid local supercheap told me they dont sell em

[buzbox]

They can order them in from ARK.

Making them call the supplier to ask the question is the key. Alot of the team member's just don't know that they can actually get it,they only know what's in store. Unlike me when I worked there... hehehehe

Longer or shorter axle, 500Hp crate engine, turbo's, whatever yep no worries I'll give them a call to see if they're available, If so I can get them in a few days.

[Jord]

I Saw the f100 hubs in trailerparts but decided to go with the 6 stud toyota pattern instead as it was only $62 for two including bearings, and as well as that i have 4 tyres and rims sitting in the shed wich are road legal still, and are 6 stud so it will save me money as i wont need to buy rims to suit.

Got down to my local salvage yard today and got 13 meters or 20x20 shs for the box carcass for 40 bucks and a full sheet of 1.6mm galv sheet that will cover the sides, front/back, and the new mud guards for $30.

I didn't get many photos but I got most of the carcass complete today, just have to do the upward supports for the long sides, and finish off the wings that lead into the mug guards.

The photos aren't very good as it was dark when I took them and i couldn't be bothered getting any lighting, will take more tomorrow.







so far total cost including trailer is $270

[Jord]

Did some 3d models this morning of how the tray will eventually, sort-of look

[larry]

models look sweet as, any rough idea of total weight or just seeing as you go?

[Jord]

just seeing as i go really, but its 80% finished at this stage and im still lifting it around by myself and its not a worry at all, under 60kg for sure at this stage

[Jord]

Well the weather is getting a bit of of control so I have had to call it a day before a tree falls on me!

The carcass is 90% complete now, just need to weld two more upward supports on to one of the long sides, finish fitting the sheet to the walls (already cut) and cut/weld the wings that extrude from the box and it will be ready to mount to the trailer.

Once that is done I can start fabricating some mud guards up.

Carcass


Testing the mud splash guards


and how it sits currently

[fully sick coily]

nice...

[Jord]

Well the rain eased up and got some more done, finished tacking all the panels in, just need to wings as mentioned earlier, and I can start removing the old box, the floor is in really good condition so will be keeping the floor in place, just removing the old walls/mudguards and mounting it on top.

[Jord]

Got the old tray off the trailer and chucked the new on ontop just to see how it looks, its not looking all that great imo but im sure once mud guards have been made and it gets the new wheels/hubs it will look ok.

The main thing is its less then 1/3 the weight of the old tray,

[christover1]

Looks great to me.
I can picture final result, it will be fine.
But I think you need a new tyre

[jdk81]

Looks pretty good.

The plates on the sides. The front is angled and the rear is rectangular. Did you consider making the rear corners, look like the front?
I suspect it might tail whip and catch things (mangle the corner of your trailer).
As long as its wide enough to keep a jerry can on.

Great to keep be keeping the weight down!

[oohsam]

Good work man. Really like it. Does the strength of the tray need to be reinforced? Not asking becuase I know, asking becuase I dont know..basically asking if its strong enough, and will it flex/bend. Im thinking not, becuase the chasis of the trailer is what matters.

Also, How hard was it to remove the existing tray?
Cheers

[Fatzook]

Thats taking shape nicely.

What are you hoping to use it for? I only ask, because the size of SHS you have used is far smaler than any light duty trailer I have ever seen before. It may suit your needs perfectly, just not sure how it would go with all the water tanks and jerries etc hanging off it.

[Jord]

JDK 81, I Originally considered doing it that way but decided against it for the aesthetics, will probably regret it down the track once it does get mangled but for now it will do.

oohsam:

The trailers chassis should be sufficient to keep everything ridged, but that said I will be adding another two cross supports between the main rails just because the spacing is quite wide compared to my other trailer, and it will make me feel more confortable.

to remove the old tray wasnt too hard, maybe an hours work, was just a matter of grinding all the welds off and using a cold chisel the beet the shit out of it till it went pop.

Fatzook:

its mainly going to be used to lug camping stuff behind the jimny, I was originally going to use 45x45x2 ( I think that is its size) for the bottom of the frame, but as its the chassis that is offering the structural support and rigidity I thought the 20x20x1.6 would do the job, its not going to be taken off road, maybe the odd sand track / corrugated road, but never anything more than that. As for the jerry's/water tanks once the mud guard its just going to be a matter of waiting and seeing, ill keep an eye on the welds but i think it will be ok.

And if it doesn't last at least it will look got in my uni portfolio

Jordan

[oohsam]

Mate, its plenty strong to put some jerry's on there. Its not like you're gonna be loading it up with a quad bike and a few hundred kilos.

Good work.

[Fatzook]

You'll just have to watch it. Corrugations destroy everything rapildy, so just keep an eye on the welds.

Also, are you hinging the tailgate down? Or to the side?

[Jord]

Still undecided but Im leaning towards pivoting down as it has that extra bit of support/strength,

[Jord]

Got the mud guards tacked in place today, I made them pretty simple as i havent got access to a panbrake for another 7 weeks or so, but they do the job and dont look too bad.

if there is another break in the rain i will have the tray finished today ready for painting. still waiting on my hubs, wire and lights from ebay though

[Jord]

I have mostly finished the trailer...well finished until its a towable trailer again, just waiting on the hubs to arrive.

Have painted the tray with black rubber, and the rest in a ugly green, have the lights waiting to be installed at some stage today and ontop of that i have removeed a couple of leafs in each spring pack.

Instead of Having the trailer spring under axle I was going to have it spring over but considering this is going to be used for a jimyy and not a land cruiser i think ill need to go back to spring under as I didnt take into account the added height of the axle and its high!

The tail gate is also just temporary but it will do till i have access to the workshop again as I want to use the pressbrake to make something a little fancy

Note: the tyres shown are not going on the trailer, just the rims

[Jord]

I mannaged to get ahold of a nice camper tent for a pretty good price so I decided to build a heavier duty trailer that is perfectly sized for the tent.


Chassis


Basic frame


Testing Strut Position


Testing Tent out


Test fitting mud guards/side jerry/gasbottle holders


Rear light Panels

and lastly

Undercoated and testing jerries

[christover1]

Very nice.

[Jord]

Got the big trailer pretty well finished today, all thats left is to make some brackets to hold jerry's/water containers and get some stabiliser legs for the back of the trailer.

I was originally going to paint it Silver to match my Jimny (wich is still not here! however I have been given the date of 26th) but the paint shop had 4L of this hammer tone metallic blue going for $40 and couldnt say no for that price!

[Modman]

Top job on the camper. It has encouraged me to rebuild my old trailer. Good work!

[tonyevans]

I love Hammer tone blue - Looks great

[suzpect90]

how much can u pick a camper tent up for been thinking about buiding my owm trailer

[atari4x4]

you can get a roof top tent & use it ontop of a trailer, they go for around $700 on ebay.

have a look through this one for suzuki sized trailers viewtopic.php?f=17&t=8052