First Time Build Questions

[jklanier84]

Hello All,

So I'm planing my first expo camper build, and I have a few questions about the basics of design, and what I can and can not do.

I have an old PWC trailer that I'd like to modify into a 4-5ft wide by 8-10ft long expo camper. The basic plan is to build a small camper I can tow behind my Jeep when I go camping. Something that can handle light trails, washboard fire roads, etc. I do NOT plan to take the trailer four wheeling.

The good; frame is Galvanized steel, well built, and the right length.
The bad; the suspension/axle/wheels/tires are pretty much garbage.
The kicker; the frame is only 41" wide at its widest point.

I was planning on buying a new axle, hubs, leaf springs, and hardware. Then build a custom camper box on top of the frame.

So, my questions are these;

1) How wide of an axle can I put under the frame with a roughly 40" spring center?
2) How much wider can the camper box be than the steel frame?
3) Is this plan way too much work/money? New suspension parts will run me $200.

Here's what I'm working with... I've already removed the fenders, and winch, and some other misc. stuff that needed to

 

[Jmanscotch]

1) How wide of an axle can I put under the frame with a roughly 40" spring center?
Depends on what size/offset/etc wheels and tires you plan to go with. Axles vendors will note a Wheel Mounting Surface (WMS) measurement. Use this in conjunction with the wheels backspacing and aim for a wheel base that'll closely match you main tow rigs wheel base. You can also get an axle with weld on spring perches so you can customize your "spring center" measurement to work correctly, no longer limiting you to a specific spring center. I bought my axle that way.

2) How much wider can the camper box be than the steel frame?
What are you making the camper box out of? A steel or wood box would be fine extending over the frame a few inches on either side to achieve the lower end of 48" width you want. I think it'd be a bad idea to try to get the 5 foot width without using a steel box.

3) Is this plan way too much work/money? New suspension parts will run me $200.
I like the starting point of the boat trailer. I've thought about using one before as the tongue length is better than most 4x6 trailers and they're usually cheap when there's no boat to go with them. If you're not going to be going through tight turns and narrow trails, the long tongue will actually be great. It'll tow nice, back even better. For reference, my trailer build is a 4x6 box with a 6 foot tongue, 12 foot overall length and I love it. It fits my needs.

I think new suspension, axle, hubs and wheels and tires will likely cost you closer to $500-600 if you can source used wheels/tires. So add a couple hundred more for a wood box and misc latches and hardware and you could have a very usable setup for well under $1,000 if you're resourceful, which most would consider a worth the time/effort/cost.

I say go for it and keep us posted through the process!

Jake