DeMented Toys $500 Excellent Adventure Trailer Build

[thetonka]

Anyone know the best way to use/set up this solar panel?

Make a mount that lets you angle it towards the sun. Hook it up to a good charge controller to charge a battery, or battery pack. Then use the power from the battery.

As big as it is you'll have to think of a clever mount and location if you are going to put a tent on top of the trailer. Based on your fabrication skills, I think you should be to figure it out. :victory:

 

[DeMented Toys]

So I talked to a local Solar Installer and he said to use two 6v batteries hooked together instead of a 12v because then I would have 2x the amp hours.... I think that means they will last twice as long between charges?

The panel has a mount on it already so I'll just have to build some type of bracket.

 

[thetonka]

So I talked to a local Solar Installer and he said to use two 6v batteries hooked together instead of a 12v because then I would have 2x the amp hours.... I think that means they will last twice as long between charges?

Not quite accurate. It depends on the Amp Hour of the batteries. There are some REALLY big 12 Volt Batteries that will have more amp hours than 2 small 6V batteries.

The amount of amp hours is the amount of power you have to use. It gets pretty complicated, but in general assume you can safely use 1/2 the amp hour before you start effecting the life of a true deep cycle battery.

Most 12V batteries are NOT deep cycle batteries, in that they really can only use maybe 1/3 of the amp hours before you start effecting the life of the battery, some even less. The typical 6V batteries people recommend are true deep cycle batteries and will handle deeper discharge and last longer.

They are also heavier, so keep that in mind.

Do some research on here, there are some really good threads on batteries and battery selection.

The panel has a mount on it already so I'll just have to build some type of bracket.

There you go.

 

[DividingCreek]

The solar panel is about 2'x4'. It was putting out 13-14 volts outside the shop this evening.... Guess it's time to do some research.

nice score. big and fragile but great price. eager to see how you utilize.

Not sure how heavy duty you want to go with the floor.
A neat product I have used and continue to find neat uses for is Azek board. Its a pvc plastic plywood available in different thickness's and lengths http://www.azek.com/azek-sheet/ most building supply places stock it in 4x8 or 4x12 sheets. I use 3M 5200 quick dry to fasten it or to form seams @ corners etc., incredbly strong and watertight structure. http://www.3m.com/product/information/Marine-Fast-Cure-5200-Adhesive-Sealant.html

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[dwh]

According to the spec sheet:

http://www.solarelectricsupply.com/pdf/BP/BP_SX60.pdf

That panel has a Vmp (Voltage Max Power - i.e., voltage under load) of 16.8v, and a Voc (Voltage Open Circuit - i.e., voltage under no load) of 21v.

That's right on the money for a "12v nominal" solar panel. To get a "12v" battery fully charged can take up to 15v, and the panel has to put out a bit more than that.

If you put that panel in full sun and see less than 21 volts with no load, or less than 16v with a load - then there's a problem. If the panel can't put out at least 16v under load then it won't fully charge a 12v battery.



As to the advice to use two 6v batteries - it's irrelevant.

Both are just collections of 2v cells - so either way to get 12v you'll end up with 6 2v cells. The only way that two 6v batteries will give you double the capacity, is if there is double the lead and acid. You could just as easily buy a 12v battery that has the same amount of lead and acid - it'll be twice the size and weight, just like 2 6v batteries will be twice the size and weight.

100lbs of lead and acid will give you X capacity - whether it's two 50lb 6v batteries rigged in series to get 12v, two 50lb 12v batteries rigged in parallel to get 12v, or one 100lb 12v battery. The amp*hours per pound of lead will be the same whichever way you go.

Using a couple of smaller batteries can be handy to save your back, but then you'll also have to deal with extra cables so it's up to you which way you go.

 

[DeMented Toys]

The frame went on a diet today and lost about 80+ lbs of excess metal and crossmembers. I don't have an exact weight but I picked up one side and stood it on it's side to weld the bottom. Finished welding and cleaned the box and frame. Ready for primer tomorrow.

 

[DeMented Toys]

I also ordered a 12v 8 amp SunShield Solar Charge Controller. Now I just need to figure out what batteries will be best for the 60 watt panel....

 

[DeMented Toys]

Not sure how heavy duty you want to go with the floor.
A neat product I have used and continue to find neat uses for is Azek board. Its a pvc plastic plywood available in different thickness's and lengths http://www.azek.com/azek-sheet/ most building supply places stock it in 4x8 or 4x12 sheets. I use 3M 5200 quick dry to fasten it or to form seams @ corners etc., incredbly strong and watertight structure. http://www.3m.com/product/information/Marine-Fast-Cure-5200-Adhesive-Sealant.html

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A composite plywood like material would be perfect. I can't find it anywhere though...

 

[DividingCreek]

A composite plywood like material would be perfect. I can't find it anywhere though...

Yeah, I used it to make an under deck tool box on my car trailer for come alongs, chain, ratchet straps etc. Its been two years and everything in there stays bone dry. Anything that gets on the material comes right off with a little spray nine. Being plastic you can scratch/ gouge it but you have to be on a mission because the stuff is tough. It doesn't break down or discolor when exposed directly to uv and in my experience doesn't warp on a hot summer day. I used a thick sheet to reconstruct the engine hatch cover on a 24 foot baja speed boat. This is the type of engine cover that lifts with a hydrolic ram and is covered in padded upholstry. The original ply used by baja had dry rotted due to condensation issues. That was 4 years ago and a lot of hours running time on the 454 (heat) as well as people lounging on it with no change in shape @ all. 84 Lumber carries it here in the East. Most independant lumber yards will also carry/stock it. Its used to trim soffits etc on high end homes.
Don't know if you have tried this http://www.azek.com/where-to-buy/


That 3m 5200 quick dry is the ultimate as well. That can be bought from west marine @ any retail store or online.

 

[DeMented Toys]

Not counting the $95 I spent on the solar panel and charge controller, the primer and paint for the frame put me just over the $500 mark!

Here's the approximate $$$$ breakdown so far.

TRAILER
$250-Atlas Compressor Trailer
$150-metal
$60-cutoff wheels, sawzall blades, flapper disks, welding wire
$50-Rustolium primer and paint
———
$510 -still need flooring, sides & tailgate hinges. May go with water sealed plywood right now to save time & $$.

GEAR & EQUIPMENT
$75-BP Solar 60watt panel
$20-Sun Shield Solar Charge Controller 12v 8amp rating
$40-filling 2 20lb propane tanks
$30-Coleman propane stove
———
$165-need deep cycle batteries & power inverter for now, but the gear and equipment list never ends does it?

 

[DeMented Toys]

I decided to use 3/4" plywood treated with Thompson Water Seal and edged with aluminum channel. With screws and water sealant I'll have about $100 in the floor.

 

[DeMented Toys]

Starting to take shape!

 

[zukrider]

i really like this trailer and the possibilities for it are endless. i was reading through and changing this and that to fit my needs, and i think im sold on it!

thanx for posting up, and ill be watching the rest!

 

[DeMented Toys]

I water sealed the 3/4" plywood floor and screwed it down. Also started cleaning up and bolting the top together. Still trying to decide whether to use plywood or metal for the sides. The floor turned out nice, but was a PITA to get in right by myself. I sealed it to the frame and around the edges with a poly roofing sealant. It was messy and once I got it all together it was a super tight fit. If I had it to do over I would have glued the alluminum framing to the plywood edges and test fit it before putting sealant around the edges and on the frame rails. Duh.

 

[DeMented Toys]

Test fitting a fender. Still need to swap the Toyota leaf springs on.