Intro & my "Swiss Army" trailer build using '05 Tacoma bed

[1x1_Speed_Craig]

My expedition/utility trailer build using an '05 Tacoma bed

Hi,

I'm a first-time poster who has been lurking & reading here for several weeks. Thanks for all the great information in the forum!

I'm in the design/parts collection phase for a "Swiss Army" trailer that I'll be pulling behind my 2005 Jeep LJ (Unlimited). I'm in Michigan, where radical wheeling isn't readily available. While the AT and other production offroad trailers are very cool, they're overkill for my purposes, and out of my budget (I'll just continue to lust over them in my dreams :sombrero. They're also very "purpose-built", whereas I'm looking for something more flexible that I can use for hardware store runs/general-purpose use, as well as camping & trekking (mainly 2-track roads...nothing radical). I also REALLY enjoy the process of planning, design & MIG welding.

Due to cost constraints, I'm going to build the basic trailer now, and plan on adding some of the goodies such as water/110V power down the road. I want to design with these additions in mind. Reading through my list of "wants", it seems fairly cliche, but will work well for me.

Here are the details...

Stage 1

• Frame will be constructed primarily of 2” x 3” x 1/8” box-section tubing.
• Receiver mount in rear bumper for bicycle/cargo rack, if needed.
• AT multi-axis coupler & tongue bracket already purchased (thanks for the help, Martyn...another order to come soon)
• Extension tongue insert w/2” coupler for the 2-3 times a year that I need to transport my 16-ft. canoe or kayak around town.
• 2005 Toyota Tacoma composite bed for the "body". I was hashing through a scratch-build steel bed, a cookie-cutter utility trailer wood deck/side, modification using an old postal Jeep body, etc. A good "engineer-type" friend recommended the Tacoma bed option (he owns an '05 Tacoma). I found a long bed version (73.5" length) at a salvage yard, and snatched it up. I plan on using the OEM Tacoma tailgate, but will re-skin the sides with some flat sheet (steel, aluminum or plastic race car material) and add Jeep fender flares. I went the Tacoma bed route because:
  
  • The "bolt-on" bed option worked well with the fabrication time constraints I have (busy job, two kids, etc.)
  • The bed size is very good for my needs: 73.5”L x 41.5”W (between fender wells)/56.7”W (above fender wells).Bed size was good - big enough to carry 4' x 8' sheets of whatever, when needed. Many of the expedition trailers built by folks here on the forum are SO cool, but too small for my needs.
  • I won’t have to worry about corrosion with the one-piece injection molded composite plastic bed. Toyota claims that it is 90% the weight of a comparable sheet metal bet, and stronger.
  • The bed design has a couple small built-in storage boxes, adjustable tie-down tracks front & side, and hangers for boards to quickly make a platform above the fender wells for hauling 4’ x 8’ sheets of plywood, etc., or in my case, potentially as a wider sleeping platform when camping.
  • The OEM bed will allow me to easily use a truck tent of some sort for camping.
  • If I choose to do so, I can easily add a off-the-shelf tonneau cover (soft or hard) down the road.
• Axle – A Dexter 3500-lb. will most likely be used. I may also consider a Torflex axle, but have to do some more research. I understand they may not be ideal for hardcore off-roading, but again, my trailer will be used primarily for highway, with only 5-10% mild offroad. At this point, I don’t plan on using trailer brakes, but I may possibly add them in the future.
• Leaf springs – TBD (if a Torflex axle is not used).
• OEM Jeep Ravine aluminum wheels to match my LJ.
• 31” x 10.5” All-Terrain or Mud-Terrain tires (BFG MT KM2s would match my Jeep).
• Tongue box (misc. supplies only for now, but eventually it will house a battery, inverter, etc. for 110V power).
• Fuel can(s) and mount(s).
• Propane tank mount (not sure what size tank yet).
• Possible use of Yakima roof rack that I already own. I already have a set of Q-towers & Rail Riders. I may be able to make my set of 58” crossbars work, but alternately could buy a new set of longer ones, if necessary, and keep this set on my car.

Stage 2

• Truck tent – While there are ultra-cool roof-top tents, truck campers (e.g. – Quicksilver) available, I don’t intend on spending that kind of money on something like that in the foreseeable future. What I can see is getting a relatively inexpensive ($200-250) truck tent that will fit my needs & budget nicely. Storage space is also a consideration.
• Battery & inverter (110V power)
• Water tank w/pump & heater
• Outdoor water hook-up w/modular shower enclosure
• Thule SMART RV Sink (or something similar)

The Tacoma bed design:

My frame design isn't going to be anything revolutionary. It'll probably most resemble the AT tongue design. I plan on notching the inside of the frame rails and bending them in for the tongue vs. welding the separate tongue A-frame pieces onto a rectangular frame. I'll most likely add 3/16" fish-mouth frame plates on the inside of the frame rails (vertical surface). I'll probably gusset underneath, as well. The frame width will be ~41-42", BTW.

Does anyone have a detail photo of the underside of the tongue/side rail junction on an AT Chaser or Horizon? I'd like to compare my gusseting idea with what they do. I couldn't find a good view using the search tool here (and with Google).

The other frame consideration is how much extension there will be off the front of the truck box. The Tacoma bed has the fender well opening just forward of center on the bed, so I'll have to account for the fixed fore-aft axle position when designing the length of the front frame extension & tongue.

Drawings to come. I'm an old-school artist type with a sketch pad (I'll do some scans soon). In the meantime, I have another engineer buddy with Auto-CAD who offered to draw it up for me (big thanks!). More details/pics to come. Suggestions, critiques, etc. are welcome.

Thanks,
Craig

 

[The Swiss]

Welcome to the forum. Just out of interest: Where is the Swiss Army coming into play with your interesting trailer build? :ylsmoke:

 

[46flattie]

Hey Craig,
Nice to see you have a project going! Hope all is well and good luck w/the trailer.

 

[1x1_Speed_Craig]

Welcome to the forum. Just out of interest: Where is the Swiss Army coming into play with your interesting trailer build? :ylsmoke:

:jump:

Hey Craig,
Nice to see you have a project going! Hope all is well and good luck w/the trailer.

Thanks Scott. It's great to see you here. It's been a rough year for me, but I'm coming out the other side. I hope the M-416 is working out well for you. I miss having a small trailer (as you can tell).


Craig

 

[jagular7]

Welcome Craig. Another forum we meet once again.

 

[1x1_Speed_Craig]

Welcome Craig. Another forum we meet once again.

Good to run into you again, Mike! It's a relatively small world on this here internet. :sombrero:


Update: I took delivery of the Tacoma bed the other night, and am starting to take measurements for frame design.

Craig

 

[bigwalton]

It's a relatively small world on this here internet.

I don't know what you're talking about...

Subscribed. :smiley_drive:

 

[1x1_Speed_Craig]

I don't know what you're talking about...

Subscribed. :smiley_drive:

It's always good running into you, Eric. :wings: I hope all is well with you and the family. And now that YOU'RE subscribed, I'm going to do everything I can to post up pics ASAP.

Craig

 

[bigwalton]

Likewise, I was just excited to see another 1x1_Speed build thread! Hope this is an indication that things are going well for you and the girls!

I haven't been the picture hound over here that I am on the Scrambler board, but I certainly appreciate the effort

 

[1x1_Speed_Craig]

Well, here's the first official "draft" drawing of the trailer layout. The overall dimensions aren't too far off from the AT Oasis (just a bit shorter). The one consideration is that the axle placement on mine is pretty much dictated by the formed fenderwells in the '05 Tacoma bed.

Tongue-to-spindle length is ~110" (including the AT coupler).

Oh, my Milwaukee 14" abrasive chop saw is on its way, too. I sold a chainsaw I didn't need and used the dough for a chop saw that I do. :victory:

Craig

 

[Borrego60]

Looks like a nice build,might have to follow this and see it to the end.

 

[bigwalton]

Alright old school! Love the drawing

With the tongue box added on, will you just run the coupler extension out most of the time so you can still open the tailgate? One of the annoying things on my trailer is not being able to fully swing the gate in most orientations... just curious how you plan for that in the build.

 

[1x1_Speed_Craig]

Alright old school! Love the drawing

With the tongue box added on, will you just run the coupler extension out most of the time so you can still open the tailgate? One of the annoying things on my trailer is not being able to fully swing the gate in most orientations... just curious how you plan for that in the build.

Glad you approve, Eric. :sombrero: I'm all about the old-school (especially until my buddy Kelsey gets it drawn up in Auto-CAD).

My plan is to use the AT couple as-is (without an extension) most of the time. Since I'm using their coupler, 50-degree tongue bracket, etc., the tongue will be the same dimensionally as all of the AT trailers. I'll have to do a search to see what I can find regarding how well the swing-out LJ/TJ tailgate clears without extensions.

The extension would only be used once in a great while to carry a canoe/kayak. It'll just use a standard 2" ball/coupler, though.

Craig

 

[1x1_Speed_Craig]

Well, here's the first official "draft" drawing of the trailer layout. The overall dimensions aren't too far off from the AT Oasis (just a bit shorter). The one consideration is that the axle placement on mine is pretty much dictated by the formed fenderwells in the '05 Tacoma bed.

Tongue-to-spindle length is ~110" (including the AT coupler).

Oh, my Milwaukee 14" abrasive chop saw is on its way, too. I sold a chainsaw I didn't need and used the dough for a chop saw that I do. :victory:

Craig

Any feedback on the tongue length relative to the axle location (which is "fixed")? I completely estimated the COG based on the trapezoid-shaped tongue box (I may buy an AT model, or make one), as well as the rectangular cargo box directly in front of the bed. I estimated a 10% tongue weight, which gave me a 110" tongue-to-spindle measurement.

I need to pick up the steel soon, but wanted some validation/feedback on the length of the trailer first.

Bueller? Bueller? Bueller? :sombrero:

Craig

 

[elmo_4_vt]

I think it depends on how you mount your equipment... If you put a lot of weight in the front of the bed and cargo box, then you should be alright with the way you have it. Depends how well you did your weight calcs. Truthfully though, I think you'd be alright with how you have it. Just remember to add all the heavy stuff as forward as possible (battery, propane, etc.) The trailer looks like it will still be relatively light, and the lighter it is in comparison to the tow vehicle the less it matters, not that that you should try and design it the right way. Just lengthening the tongue won't do you much good.

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