Coleman Colorado rebuild

[OverlandZJ]

Hi Guys, been awhile since I logged a project on here. Haven't slept a night in the woods since 2012 and I'm sick of it..

Different rig and a small pop up have replaced the older gear. I have found locally two Coleman Colorado's in need of repair, one much worse than the other. One has a replacement canvas that I hope is still salvageable after 4 years and the other needing floor repair and canvas replacement. The idea is to clean the Bear Creek replacement and install on other trailer.

My plan is to strip the better trailer to the frame, reinforce the frame a bit and reassemble with all new wooden structure. I'd like to ask those who have rebuilt if they have done any reinforcing, it looks to me as though the Colorado's frame could use some.

Here's a pic of a stock frame, photo credit to JetNoise here on the forum. He shared his PB account and I'm glad he did, gave me tons of ideas and sold me on one of these trailers.

I think I'd like to start by adding a few crossmembers, extended tongue, rear receiver, and boxing in the sides of the trailer a bit better. Suspension and axle swap may have to wait, a spring over and larger tire is planned. Unsure on size as yet, need it to ride level behind a ZJ on 31's.

Anyone have any input on how they beffed up their Colorado? Short of slipping an M116a2 under it.. which is a great build BTW.

Here's the setup as it sits today.

 

[OverlandZJ]

OK, so no input on the frame strengthening. I think i'll be cutting the two center crossmembers shown in pic abaove.. and add them to the other frame.. one fwd and one at other end. Some other strengthening, i'll get to know my 110 Lincoln welder finally.

How about rebuilding the box. 3/4" Marine grade plywood or something else? Composite maybe?

I'll be dragging this over to my son's place and backing in garage in a few weeks, like to have it rebuilt in roughly 2 months. Like to spend my birthday in it on it's first time out.

 

[ratled]

tagged

 

[Waygoner]

My $0.02 - I like the corner braces it has up front. I'd add those to the back. If you're going to extend the tongue, you might replace it and run it all the way to the back.

 

[OverlandZJ]

My $0.02 - I like the corner braces it has up front. I'd add those to the back. If you're going to extend the tongue, you might replace it and run it all the way to the back.

You have a good point on the corner gussets, and yesterday we realized that the second trailer also has the adjustable supports.. both will move over to the better trailer.

On the tongue, I'm wanting to add a water tank centered above axle.. if I incorporate the tongue and rear receiver I wont be able to install/remove tank.

Yesterday I towed the trailer to my son's house, he has a 3 car garage and plenty of room for the project. We tore the old canvas off, removed and inspected bows. Some need work or possible replacement from my second parts Colorado.

I never opened this trailer when I purchased it, although I had several photo's. The rear right corner was soft and the issue that had owner sell it after tearing into it and reconsidering. The whole floor to the side of frame rail seem to dip down.. I definitely need to gusset the corners.

Photobucket is being wonky.. i'll share a few pics later.

In the meantime I need to search for a wiring harness and LED tails/marker lights.

 

[jd350az]

Very excited to see this project!

 

[OverlandZJ]

Found I needed AdBlocker for PB.. now I can navigate the site without freezing.

Here's a few pics as purchased, I opened it up for the first time yesterday. Pretty much as expected but with damage to a few bows that wasn't disclosed.. again I have a second trailer in much worse condition for parts. In total I have $250 into both their purchases.

The soft spot in floor where the last owner gave up..

The front bow.. bent pretty good, probably from improper closure. I'm hoping the inner sleeve is a generic Coleman adjuster piece and available if I don't have it covered.

Pushed inside and disassembled bows, took some pics of the hardware/bracketry and started looking things over and making plans. That's about as far as we got the other day. Son lives about 45min away so I wont get to work on it everyday but the plan is to have it usable come March so I can get out for my birthday.. wish me luck.

 

[OverlandZJ]

The plan is to fit up to a 235/75/15 wheel/tire package on this trailer using wheels that match the Grand Cherokee. The wheels have 5.5" backspacing and are 8" wide with 5 on 4.5" bolt pattern. The tow rig sits on 31's so i'll need to think about a spare as well.

I have a near new Dexter 2000# trailer axle in garage, bolt pattern will work but the axle is about 5" too wide at 70". The original is about 59". Neither will work so im going to order a new 65" 3500# axle along with suspension from www.abctrailerparts.com. I'm also gonna need to dremmel out the hub on the wheels I plan to use. I also came up with a plan to add crossmembers to add support to new floor including boxing of the frames corners.

Took good measurements and photo's of how the trailer came apart, hopefully it goes back together the same.

I was hoping some of the Colorado builders here would have chimed in with advice or guidance.. maybe their all in camp.

 

[OverlandZJ]

Those who have replaced and extended their tongue, what length did you go with?

Assuming most used 2x2 for an articulating hitch, and a 12' stick should be plenty?

 

[DanCooper]

You pose a tricky question, the answer to which requires you to do some measurements, make some estimates, and then do some math.

You measure the location of your axle on the frame. The rule of thumb is that the axle will sit about 60/40, with 60% of the distance measured from the hitch point to above the axle. If you want your build to be more precise, you will do it by weight, which is where the estimating comes in. See, e.g., this link.

Regardless of how long you make the tongue, I would recommend bringing that tongue much further back under the body of the trailer, at least as far as the cross member nearest the axle (and behind it is better). Putting gussets at each cross member is also recommended, as well as two diagonal pieces (one on each side) from the tongue near the hitch point and back to the second cross member.

Good luck!

 

[DanCooper]

Did you order new springs and hangers with that 3500# axle? I think you would be happier with the result if you did.

 

[OverlandZJ]

Dan, appreciate the feedback but I'm not so concerned with proper tongue weight as I am with being able to slide the sleeper and not having to unhitch. I do plan house battery/s for storage compartment at rear to maybe help compensate.. I guess what I'm saying is i'll do my best..

I do plan to order a new suspension as well, however I think ABC trailer parts as linked earlier may be out of business as they haven't returned calls. Anyone have suggestions to who to order an axle and suspension from?

Placed a small steel order today, pick up on Wednesday then to my son's place to start the Colorado's reassembly.

 

[OverlandZJ]

Ordered a new Dexter 3500# 5 on 4.5" with EZ lube spindles along with two 4 leaf springs rated at 1750lbs. Thinking these should be soft enough, if too soft I can just run down the street and grab a new set or add shocks?. Ordered the axle with no camber.

Didn't realize I had a place a few miles down the road, nice folks and a good inventory on hand. http://www.hennesseytrailers.com/

Friday I pick up my steel order and start reinforcing the frame. Here comes the fun part of the project.

I still haven't decided on the tongue yet, whether to run full length or even what material to use. I'd like a ball mount but may see if I can swing an articulating hitch.. and whether or not I even need one.

 

[jet noise]

Just now seeing the thread, ZJ. Looks like you've got some great ideas going! One thing I noticed about mine when I lived in AZ...It would go anywhere but all the bouncing off road is hard on it. I air the tires down but some shocks would be even better.

 

[OverlandZJ]

New axle, leaf springs, 2x2 tubing and additional steel pieces are acquired and stored in garage.

The leafs have a 1" wider requirement for the hangers, i'll be cutting off the rearmost at slider bolt and replacing for a shackle hanger (which I forgot to order along with shackles). I think i'll make them both..

The 2x2 tubing will be to box out the corners of the trailer, in front and behind tires on both sides. This will prevent the flooring from bowing down on the outside portion of floor beyond the main frame rails. I have wider c-channel I'm repurposing for between rail crossmember's to support between the factory z shaped crossmembers.



Above is what I'm leaning towards for a tongue. If I'm correct it's 2x2 from under trailer to a 2.5"x2.5"(receiver) back to 2x2 with the 1 7/8" ball coupler. Sound like I have that right?

Jet- Thanks for checking in! I'll be away for a few days for a surgical procedure but hope to home by the weekend to maybe head over my son's place and tinker a bit to get this project restarted.