Expedition Trailer - Custom Build

[AlexJet]

I'm finishing my build of the Expedition Trailer. The basic stuff is done; so far wiring is under work and may be several small upgrades as well. In my opinion, based on my nature, the upgrade process will continue for a long time.
I'm writing a write-up on the build and posting it up on another forum stage-by-stage. I was thinking of placing a short story on this forum as well. Would be this section appropriate for such write up and is there a demand from other members to see it?
I'm also was thinking that an Expedition Style crowd could suggest some upgrades for the finished product.

 

[Box Rocket]

Yep appropriate. Post up.

 

[G-force]

Yepp, go for it.

We can take it:bike_rider:

 

[AlexJet]

Ok, I will.

 

[G-force]

Thanks.

Looking forward to see the pics.

 

[AlexJet]

Thanks.

Looking forward to see the pics.

Need to finish wiring. Allot of work in time consuming but very little in appearance (wires and connectors are not that noticeable )

 

[AlexJet]

Last night I received LED back-up lights, so I'll be finishing wiring (back-up lights, interior lights and trailer-to-vehicle connector), mounting some accessoreies and upgrades this week. If everything will go as planned it will be road worthy by the end of the weekend.
Pictures will come right after it will be done. Stay tuned...

 

[maXTERRA]

As always, threads are completely worthless without pictures!!!
(so hurry the he'll up willya!

 

[AlexJet]

As always, threads are completely worthless without pictures!!!
(so hurry the he'll up willya!

I'm trying, but having temperature below freeze mark outside doesn't actually helps and accelerate the work.

 

[GTKrockeTT]

how about a link to the other forum's write-up?

 

[AlexJet]

Sometimes link is good, but I'll do a short story here with pictures, so it will be much easier to read.:smiley_drive:

 

[AlexJet]

BUILD:

Ok, I'll start posting some info even it's not finished at the time I'm writing this lines. I'll be doing updates as soon as I'll get more done.

At the beginning I was investigating if I can buy a Ready-to-Go one. There are plenty of options to choose from if you do spend some time to research. The major issue is to bring it to Canada as all manufactures are over the border. With exchange rate, customs, brokeragee and taxes anything you can find even in States nearly doubles in price after you bring it to Canada. Even basic Chaser here would run about $10k.
So the soultion - Build.
You can start from scratch or get utility trailer and modify it. Basic frame build from scratch will cost ~$800 in metal (its expensive here), Home Depot/Lowes 4x6 or 4x8 are $1k +tax. After looking around and checking the prices I went with 3rd option - Re-build Pre-build boxed frame. I found boxed 0.120 wall 4x6 frame for $200 and 3'500 lbs axle from double-axle trailers for $50 cash. It was a good deal.

This what I started with:

First was to size it to what I need. Read - cut all unwanted pieces.

Reinforced and re-welded frame for my project:

I used Jeep YJ Superlift springs:

Re-fab the axle:

Added Rancho Shocks:

Used Adapters to convert to Toyota bolt pattern:

Start welding box frame supports from 1" square 0.100 wall tube:

Then added walls:

Made provisions for a water cans:

 

[AlexJet]

Made a frame for the fenders out of 1.5"x1.5" 1/8" angle and 1" round DOM 0.120 tube and 1/8" aluminum checker plate fenders:

Installed the front tongue box:

Install the lights and wire all up.
Groomets were used in all goi-through parts:

Wire-up the lights with plastic wire protection:

More to come ...

 

[maXTERRA]

Damn nice looking job so far! Looking really good.

 

[AlexJet]

I want to add my Great Thanks to Martyn from Adventure Trailers for his support in parts. His Max Coupler is an amazing device. I didn't had a chance to see it working yet, but so far its just piece of art. To be honest first I considered Lock-n'-roll one, but after washing my brains for 2 month, I decided to drop all work with them and use AT services. I should of done it at the begining, just the other guys were close by in Michigan, while artyin is in California. Highly recommend AT over other suppliers.

I do have a few tweaks and upgrades which I'm working on. I know some would say that I didn't finish it yet, while already doing upgrades. May be it is because my mind is working faster then hands and I see things way ahead. Working for Aerospace company make it lifestyle of thinking ahead of things happening.