2006 Fleetwood Neon - Mountain Fort Build

[steamhammer]

Just picked up this Neon, and took its maiden voyage a few weeks back. Boy does this suspension need work. This thing rides rough. I plan to rebuild the suspension for better performance on moderate dirt roads. Looking forward to building this out and sharing for any other Neon owners out there wanting to modify and improve their setup.

 

[steamhammer]

Leaf Springs-

I am not a fan of this slipper spring. Initially, I pulled out a leaf, which actually gave me some decent springiness. But that ultimately left me feeling uneasy for loading it up and I really just don't like the mechanics of a slipper bouncing around in the retainer. I purchased a set of double eye leafs rated for 650 pounds each. They're longer than the stock 25'' leaf at 29'', and the trailer frame has sufficient length spacers to accommodate welding on the new hangers, with the axle center in the same position. Both frame spacers were already square to the tongue within a 1/16'' (good on ya Fleetwood) so they made good datums to locate the new hangers. I wanted a bit more angle on the shackle, but I had already cut it off and relocated it once. Oh well, at least I'll get maximum clearance (I got 1'' of lift out of this). The shackle sits vertical when the springs take on the vehicle weight. I have about 1.5" of down travel now, as opposed to less than .5" with the slipper. Now I can push on the trailer and make it sway. I could barely make it budge before, even sitting on top of it.

 

[Roam.Wild]

Are you using this offroad? I'd look into adding some shocks. We added some to our little overland leaf spring trailer and it made a massive difference in ride quality and stability.

 

[steamhammer]

Shocks-

With the leaf springs located and installed, I was able to measure for shocks. I went with a set of Monroe 5752 - 4'' travel, 8.625'' compressed. Their vehicle application is a similar weight range to a loaded trailer and they have relatively appropriate dimensions. I ziptied the shock in a mid position and split the travel 60/40, biased towards more uptravel. I loaded up the trailer to compress the leaf springs into a more realistic driving position. The trailer frame doesn't have a great option for upper shock mounts, so I fabricated a cross bar from a piece of 2x2x1/8 angle, and had to cut out some windows for the pop up lifting cables. I gusseted the shock mount locations and the cutout windows to help resist the twist. I tacked the upper shock tabs in the highest position I could to the crossbar, and offset them as close to the leaf spring as I could leaving some clearance to get the welder in there for the lower tabs. Then I bolted up the ziptied shock, bolted the lower shock tabs to the shock, and was able to play with the crossbar location, sliding it closer/further from the axle. I chose a position between a vertical shock and having the lower tabs protrude below the axle pad.

 

[steamhammer]

Wheels-

I want to make it easier to move the trailer by hand, but also keep the weight down. The small stock tires feel every little bump, so going with larger tires will also help smooth out rough roads and trails. I upgraded to a 15'' rim to have more tires options to choose from. The stock 20'' tire came on a 10'' rim, really limiting choices. I kept the same 5 x 4.5'' bolt pattern. These d-window rims came with a -6 mm offset, but the tire sidewalls were still able to clear the trailer. I wanted a tire with decent sidewall protection, and not too wide. I went with General Grabbers AT/x 215-75R15 since they came in a 215mm width, so not too much wider than the stock 205s. They are just under 28'' diameter. The stock leveling jacks still work (with a 4x4 block), the rear step is noticeably higher, but manageable. I did have to cut off the steel fender brackets to give the tire enough travel clearance. I cut out one of the stock battery mount angles, and the spare fits perfectly in the tongue.

 

[buyrovers]

Sold my neon a few months ago but they are great little campers

 

[steamhammer]

Sold my neon a few months ago but they are great little campers

Did you often take it on any bumpy forest roads? I'm curious how well the body will hold up over time.

 

[buyrovers]

Yeah some national forest type roads with bad washboards etc. I just took it a little slow so it didn’t rattle the thing apart and never had an issue. The upside to the neon is it’s super simplistic so it can take a bit more abuse.

 

[buyrovers]

I had oversize tires on it as well which I think helped a lot. There are a couple build threads on here if you haven’t found them already