Expo-Lite

[REasley]

I have been lurking here for the past few months, looking for ideas for my upcoming trailer build. While I have seen some wonderful trailers built by very skilled people, I have yet to see something that will fit my application.

My tow vehicle is a Suzuki Samurai (actually by choice), which limits me to 1000 lbs gvw and I think the zook, being a stock 1300 cc beast will even have trouble with that much. So I am attempting to build the lightest possible trailer and still carry the stuff we need.

I have decided to use some semi custom aluminum boxes built from .10 marine grade aluminum as the structure of the trailer, with a light steel frame to carry the running gear and coupler. Sort of a semi monocoque design. The steel undercarriage will be built from .063 wall 2” square tubing with reinforcing for the spring ‘mounts. The tongue is a sliding affair - a 2” 3/16 wall tube that slides into a 48” 3/16 receiver tube. The coupler is a Max coupler from AT (thanks Martyn). The alu boxes are 60” long and 24” deep. One is a top opening box and the other is a drop front (the kitchen). A 48” tongue box sits in the front. A 20 gallon water tank will be mounted over the axle, between the frame rails and a 12 gallon fuel tank & pump will stowed away in the top opening box

Here is the initial drawing and parts list

 

[Maximus Ram]

Welcome to ExPo.
Look foreward to watching this come together..:ylsmoke:

 

[indiedog]

Sounds like a fun project. And your parts list puts my effort to shame!

With you GVM of 1000lbs you would have to eliminate absolutely everything on the trailer that isn't needed. And it obviously depends on what you are carrying as well as to the configuration of the trailer.

I'll be very interested to see what you come up with!

 

[compactcamping]

REasley, look forward to seeing how it comes out. It's always fun coming up with a suitable balance between lightweight and durability.

Here is a plywood based trailer I built that might give you some ideas. It's 4x6 and was 393 lb empty. On the front deck there is room for a cooler and two 5 gallon water jugs. My old Tracker had no problem towing it.

 

[gjackson]

Welcome. That's a pretty detailed parts list you have. Look good; I'm looking forward to see how it develops.

cheers

 

[REasley]

My first thought was to just get rid of the zook and buy something big, new and shiny, but the zook is like a dog you've had for a long time. We've bonded.

The detailed list is because I am a buyer for an ag and industrial supply company and I do most of my work on spreadsheets. The list was easy. My company stocks all but about 5 of the items, so I could just download the info to the list. A few of the items like the boxes and the axle were stock, but I was able to have the mfgs make a few changes and ship with our stock orders

I am a little stumped on how to hang the water tank between the frame members. The tank is 5" at one end and tapers to 3 3/8" at the other. I would like to be able to remove the tank should repairs become neccessary. We have very large stainless steel hose clamps that could incircle the tank and frame but the bands are only 9/16" wide and I am afraid vibration would cut into the poly tank. Any Ideas?

 

[stevec]

Your project is along the same lines as what I would like, as I too drive a Sammy (had it since new in 1986). The biggest variable I see in your design is your 20 gal. water tank and 12 gal fuel tank - that's 240 lbs of water and gas, or 1/4th of your total weight. I suppose you don't have to fill them all the way full though.

I like the idea of the carrier for the tank. If you just use straps that are 9/16", maybe some 1" wide rubber between the straps and tank. That would dampen vibrations, and if anything, the straps would only cut into the rubber.

Do keep us posted - this sounds like the build I've been looking for here.

 

[OlympiaFJ60]

Or use 2"x3/16 strap like gas tanks use, and bolt it to two of the cross members. That is what I have planned for mine. Do you have any pictures of the tank you are going to use?

 

[OlympiaFJ60]

Here is a plywood based trailer I built that might give you some ideas. It's 4x6 and was 393 lb empty. On the front deck there is room for a cooler and two 5 gallon water jugs. My old Tracker had no problem towing it.

Did you build the trailer or was it a ready made and you just replaced the decking with the box. Looks great.

 

[REasley]

I purchased the Ronco tank based on it's size, profile and price. It's actually a holding tank, buts it's rated for potable water. http://www.tank-depot.com/productdetails.aspx?part=R-24H#

I was thinking I could use hot water heater earthquake strap held in place by the hose clamp, but I like the idea of th 3/16" flat stock. I could bend to shape and thru bolt to cross members of the trailer frame. Thanks

 

[REasley]

Stevc
I've struggled with the weight issue regarding the weight of the water and fuel. Both tanks will be empty on departure. I live in the foothills of the Sierra Nevadas, so to go most anywhere fun I have to go up. I can fill the tanks on the road with as much or litttle as needed.

 

[compactcamping]

One thing that might be a problem with a lightweight trailer is a "septic tank" most likely doesn't have baffles. Sloshing water might cause handling challenges.

If you're worried about the straps cutting into the tank, use something like 1/16" neoprene between the tank and strap.

 

[compactcamping]

OlympiaFJ60, Thanks, that frame was a bolt together squaring tubing 4x6 flat bed frame by Magneta Trailers.

 

[REasley]

Compactcamping

I thought about the sloshing, but the low profile water tanks don't have baffles either. We'll see if it's a problem. I can always go to outside tanks

 

[stevec]

I live in the foothills of the Sierra Nevadas, so to go most anywhere fun I have to go up.

I'm very partial to that area - I was born in Hangtown, and grew up in GV and Auburn. My wife is from Sonora. Lot of places to explore around there.

Besides keeping the weight down, you've already addressed brakes, so you'll be in good shape, as long as you aren't in a hurry to get where you're going!:smiley_drive: