rustED's Expedition/Utility- Double Duty trailer build

[rustED]

Hello, new forum member here. I just recently discovered Expedition Portal forum, and after reading through a few builds I knew that I had to join. I started building a trailer almost 4 years ago. The progress has been very slow lately, life has away of doing that, so my hope is that by starting a build thread here it will light a fire under me to get this thing finished up! When I started the project I was without a pickup. I had sold my dd ford F150 to build my dream Toyota 4runner, so I my goal for the project was to have a utility trailer that I could also use for camping and exploring some rougher terrain. Over the next few days I will post up pics to show the progress up to it's current status. I'm open to all questions, comments, and suggestions. As all really SLOW projects go, enough time has gone by since I first started this project that there is a lot of things I would have done differently. I will try to comment on these when I get to them, somethings I might change eventually, but my priority is to get it functional by this spring, then make changes as time/money allows. Thanks in advance for looking!


^Here's a pic of the main frame under construction. Dimensions are 50"Wx86"L and is built out of 2"x3"x.125"Thick tubing. The trailer tub 73" long. That will leave a 13"x50" area for jerry cans storage etc before the tongue. All the tub frame work is 1" square tube. The stringers are 18" on center and line up with the stringers on the main frame.


^I used gussets in all the corners of the frame


^One thing I had to change was the width of the trailer tub. The main trailer frame being 50" wide, if I made the tub flush with the main trailer frame width, the tailgate opening would have been exactly 48", which would have made it difficult to slide plywood or sheet rock into without getting it wedged and stuck in there. So I made the tub frame work width 52" and overlap the main trailer frame sides. This is one thing I would have done differently, I would have made the main frame 52" wide to begin with. In the first pic you can see howhat the tub frame work overlaps the trailer frame. The tub measures 73"L x52"W. The sides of the tub are 24" high if you count the 3" that overhangs the main frame. Inside the tub is actually 20" deep.

 

[rustED]

3-Link Suspension

Did I mention I'm doing a 3-link? I was originally going to use jeep TJ coil springs, but ended up getting Firestone airbags. This is something I would do differently as well. After reading Wood's "light weight rock crawler trailer" build, I wish I would have built a trailing arm suspension. This is something I might changet in the future, but since I'm nearly done with the 3-link, I'm going to go ahead and see how it performs.


^The axel is rated at 3500lbs. I think it's 61" from wms to wms, which ended up being another problem I had to remedy. After widening my tub and over lapping the main trailer frame, my tires where rubbing, so I had to buy wheel spacers.





^built the trailer tongue. I'm going to go back and plate the area where the gussets are. I also plane to add a receiver tube so I can switch hitches from a ball to a 360° swivel/Offroad hitch.


^Started skinning the trailer tub with 14 gauge sheet metal. I used one 5'x10' sheet for the floor because I didn't want any seams. And one 4x8' sheet pretty much did the sides. I had enough left to skin the front of the tub and the tailgate. Unfortunately not enough left to build fenders, but I did have enough scrap to build a handy lockable armrest/storage box with cup holder for my 4runner!

 

[rustED]

Tailgate




^Another thing I would have done differently is I would have made the tailgate 1" taller, and moved the tub stringer forward 1" so when the tailgate was opened it was flush with the trailer floor, as it is currently, it's elevated an inch higher than the floor as you can see in the top 2 pics. I'm not sure this will really pose any problems, it's just one of those things I look back on a and it's like, " what was I thinking"!



^One thought I had was by putting the tailgate handle on the inside, and with a hard tonneau cover closed and locked, there was no need for a lock on the tailgate...we'll see how that plays out, I may need to change that also.

^Added a place for the license plate. I will fab up a rear bumper and mount the tail lights in it.

 

[rustED]

^Here's a pic of my tow rig. Its an 86' 4runner, has a straight axel swap, and a Ford 302 V8.




Here's my trailer with a matching 35x12.50 on it. I also got a electrical panel from work that they were throwing out. The door is weatherproof, just need to patch the holes where the conduit came into it. Going to use it for a tongue storage box.
So this is about as far as I have gotten on the trailer. I still need to finish one link, mount the Firestone airbags and plumb in the air lines, buy some tabs to mount the link to the axel and to the frame, finish one tailgate stop, finish up the trailer tongue, build a tonneau cover, build some fenders, figure out all the wiring, and a bunch of other stuff I will think of later.

 

[rustED]

I got a good deal on some 2" wheel spacers off CL, should fix my over site on the axel width, I guess that's what happens when you start changing dimensions halfway through the build, lol.

 

[highlandercj-7]

Looks like your going to have a nice solid trailer. I like the runner as well. That V-8 ought to make sure you have no issues towing the trailer too.

 

[rbkelley89]

^Here's a pic of my tow rig. Its an 86' 4runner, has a straight axel swap, and a Ford 302 V8.




Here's my trailer with a matching 35x12.50 on it. I also got a electrical panel from work that they were throwing out. The door is weatherproof, just need to patch the holes where the conduit came into it. Going to use it for a tongue storage box.
So this is about as far as I have gotten on the trailer. I still need to finish one link, buy some tabs to mount the link to the axel and to the frame, finish one tailgate stop, finish up the trailer tongue, build a tonneau cover, build some fenders, figure out all the wiring, and a bunch of other stuff I will think of later.

so how long is that tub it doesnt look like 72" was that just the frame length up to where the tongue box starts

 

[HAFICON]

Very nice.. Frame looks great.

 

[rustED]

Looks like your going to have a nice solid trailer. I like the runner as well. That V-8 ought to make sure you have no issues towing the trailer too.

Thanks for the compliments! I hope it turns out good, I've never done a 3 link set up, so we'll see how it goes, I have one more link to install to finish that up. Someday I might change it to a trailing arm settup. I'm pretty happy with my 4runner, it has plenty of power, even with stock 4.10 gears and the 35" tires. I've been daily driving it for almost 3 yrs, and its been really reliable. Its still a work in progress as well, I think that part of the reason my trailer has taken so long, I've had to split my limited time and funds between the two projects, lol.

Does anyone know of a detailed write up on trailing arms suspensions? I'd like to do so e research on that incase I'm not happy with my current setup, Thanks!

 

[rustED]

so how long is that tub it doesnt look like 72" was that just the frame length up to where the tongue box starts

I just went out and re-measured since it's been so long since I worked on it last, it's actually 73" with a 1" overhang around the top of the tub. Its 52" wide. Its probably those 35" tires that make it look shorter in the pic, lol.

 

[rustED]

Very nice.. Frame looks great.

Thank you! I still need to finish the tongue, and finish welding the gussets, I plan on adding some 1/4" plate triangle gussets for additional strength. I really wish I had a heated shop to work in instead of my carport!

 

[rustED]

At work tonight all I could think about was how I'm not liking the idea of running the 2" wheel spacers. My toyota has a wms to wms of 58", currently my trailer axel has a wms of 61". By the time I add the 2" wheel spacers it will be 65". I'm worried it's going to look out of proportion, like it should be pulled behind a Hummer H1 instead of my toyota, lol. I'm really starting to consider notching the frame so I can keep my wms at 61" and building some mini wheel wells.

If I go this route and notch the frame, I will probably have to remove the crossmember that has the airbag mounts welded to it and modify it. I was thinking if I go this far I might as well ditch the 3-link and build trailing arms. What do you guys think? I'm open to your opinions/suggestions, thanks!

 

[rustED]

Does anybody know of a thread that has a detailed description on building trailing arms? I've come across a couple, but either the picture links don't work, or they don't list alot of specs on how they were built. Just looking for ideas, I'll continue searching as well, thanks!

 

[GeoTracker90]

Hey there rustED, I know that you saw this thread linked over on my new build thread, but I thought I would add the link here as well so anyone following your build could go check it out as well. Here it is:
Home Built Independent Suspension

Good luck with your build! I'm excited to see how this turns out for you.

Mike

 

[yj4trails]

Hey rusteED... I am in the same boat as you with having an uncompleted trailer project. I like your tailgate hinge is that a stock piece off of a truck tailgate or did you fab it yourself?

Just my opinion but why not leave the trailer as is and use it first before making any big changes. Get narrower tires for the trailer and then it won't look as wide.....