Was up until 2am reading through about 50 pages of this thread spending time in any DIY Trailer build thread I could find. I thought it would be a great idea to start a thread where people can ask some of you DIY Expo trailer builders questions. Even after about 5 straight hours of research I came away with a lot of questions. I realize it's hard to get concrete answers because every trailer is custom built to what each owner wants but there has to be some ideas on a few of my questions so let me start asking away and hopefully some of you DIYers or even those of you building military type trailers can chime in and help answer.
1. When building a trailer do you build it around your axle? Meaning do you buy your axle first then decide trailer dimensions after? Or is it the opposite. Do you build up a frame and then order an axle to fit your frame.
I built mine to the tow vehicle. In my case it is an LJ with 60" wide axles so that is where I started.
2. Frame building materials. I've seen everything from Square tubing to C channel to angle iron. Why did you do what you did and what size material did you use?
I used 3x3x.120 for the tongue, 2x3x.120 for the main frame, 2x2x1/8 angle for the cross members, and 1x2x.095 for the superstructure.
3. As far as the trailer tongue goes how long is optimal so you can basically jackknife without hitting tow vehicle? Also what size tongue material is used to fit your hitch on the trailer size?
Mine is 4' long plus the hitch. It just has a regular ball mount now but I may go to a difference set up.
4. How do you locate where to put your axle and axle hangers?
Mine is a little different here because I wanted it not to matter where I load stuff. . .so it is 25/75 front/rear. It looks a little goofy and, contrary to what everyone would think, it tracks around corners very well. I think that is because it is still a short trailer. The other issue with shorter tongues is that they are very difficult to back up when you don't want to jack-knife them. I get the pros and cons but this works for me.
5. What is the ideal size of an off road expo trailer for an RTT raised above the lid of the trailer? And how tall should the sides be?
You want to make sure that it is at least as far off the ground as your ladder is tall. Mine is 4' to the bottom of the RTT. OR, you could build a lift system. I like KISS.
6. What is the typical cost breakdown of a trailer build ie Axle cost, materials cost etc?
I'm $600 in to mine plus the RTT so far. All brand new stuff except for the tires which were new spares from a couple of my Jeeps.
7. Where did you source your axle from and do you use brakes or no brakes?
No brakes and Amazon.com
8. What size axle is best to use. Looks like most people buy a 3500lb. Where to buy?
It depends on what you are going to do with it. Mine will never weigh over 1200lbs loaded and I use 225/75R15 tires, not 35s to match the Jeep. Why? I'm a function over form guy. trailer that weighs less than 1/4 of what the Jeep weighs will never need that much flotation. Ground clearance isn't an issue because nothing hangs down. It still has more clearance than the Jeep on 35s. So, bigger tires and bigger axles just create more unsprung weight and drag. The argument for carrying one spare is weak. The only reason to have it all match is that it looks good that way. I get that. . .but I'm a hack.
9. What size leaf springs? Where to buy
1000lb trailer leaves from Amazon. However, I would like to play with a set of XJ leaves I have in the shop along with some shocks. The trailer rides great with camping gear on it but it is a little bouncy empty in the mall parking lot.
These are just some of the questions I have about taking on and building a custom trailer. I'm sure I will have more but this should get me started. As I am saying this will be my first attempt and I will start a separate build thread. Just thought this would be a great place for potential builders like me to ask questions and hopefully get some interest from those of you who have been there done that giving back and answering our questions......