1985 Packmule Trailer Rebuild

[Bigthom]

I have seen a couple Packmule trailer builds on this site, I was unaware of the brand when I came across this one from a friend of a friend. It was lawn art and he wanted it gone ASAP. According to the owner, it had been sitting since 2000. Aired up the tires, hooked up the lights and dragged it home without issue. The trailer was rusty...very rusty. The hitch was suspicious and the axle was sagging at different rates. I knew I was in for a new hitch, axle and paint at the very least. The trailer came with a giant water tank bolted to the front, fuel carriers on the side a spare on both sides in front of the fender. This trailer is significantly longer than most Pack mules I have seen. I got it home a stripped it down, removing the fuel jerrys and recycling the contents. I removed the lid, spare wheels and associated parts. Gave it a good power washing and removed the birds nests

 

[Bigthom]

Once I got the trailer in the garage and up on jack stands, I removed the wheel and started to get an idea for suspension. I really liked the axle-less suspension from Timbren. The cost however, made me look at other options. I ended up ordering a 3500 pound torsion axle from Southwest Wheel and Axle. I exchanged a few emails and they told me I had to order a 3500 pound axle if I wanted to run 6-lug wheels. Then, they down rated the suspension for my uses. I went with a 2000 pound load. I provided the frame width, hub face measurement (accounting for different wheel offset) and bolt center to center. This is a bit stressful as there are no returns or exchanges. You have to get it right. I hacked off the dodgy coupler and ordered a Lock N' Roll hitch, installing with Grade 8 hardware.

 

[Bigthom]

I stripped off the lights, brackets and associated paraphernalia. The spare tire mount was not going to work for me and the lights were toast. Tore into the rust with an orbital sander, needle gun and grinder with varying levels of PPE. After the rust was removed, I treated many spots with converter and then slapped a few nice thick coats of red oxide primer. This took a lot of time. Rust removal should not be rushed. I have experience with painting metal from my time in a sea going service. I really enjoyed this return to my Semper Paratus roots.

 

[Bigthom]

For paint, I went with Massey-Fergeson tractor paint. I used a technique I have had a ton of success with previously that we call "dry brush". I cut in the edges and corners, rolled on the paint with a foam roller and then dragged a dry brush across and then down the still wet paint. The result is a thick coat of paint with little to no orange peel. For the tub, I used truck bed liner. The axle arrived and I sourced some FJC steelies, which are the same rims I run on my 4runner. I picked up some off market used mud terrains from a wrecking yard. After checking fit, I primed and painted the axle and bolted it up. Fit perfectly!

 

[Bigthom]

The rest is just finishing touches...Installed extra tall rain gutter racks and crossbars. These were mounted to artificial rain gutter mounts. I'm not convinced I will keep this system, I really like it, but may change to a more permanent rack. Left the bars long to support my Yakima box and my swag. I added new fuel carriers to the front of the trailer. I made mudflaps from 4 dollar floormats and grabbed a new tongue jack (which I will change as the handle hits the spare tire). For a spare mount, I bought a hitch mounted carrier and clamped it to the tongue facing backwards. Its rad. New LEDs and mounts for a shovel and a pulaski. I am in it for about 2300. I am really happy with the way it turned out...I'll use it for a bit before I start a battery system or any other add ons. Thanks for checking it out!

 

[DanCooper]

Very nice work!

 

[R Thomas]

Great looking trailer. I am looking forward to reading more.

Sent from my SM-G930V using Tapatalk

 

[Bigthom]

 

[sstan]

Nice build. I’m in the process of building a Pacmule too. Mine had a solid axle welded to the frame. I cut that off and have now installed Timbrens. Your tongue is much longer than mine. I’m not real keen on the stock hitch either but it did hold up bringing the trailer home while it bounced down the road. It really could jump with balloon tires and no suspension... If you still have the top and don’t have plans for it, we should talk.