M416 Trailer build

[womacje]

I have just recently purchased a M416 trailer. Frame is in great shape, axle is doing well also.

To be done:
Strip it down
Blast it
Convert hubs to 6x5.5"
Fix E-Brake housing
Weld in reciever into rear of frame
Weld Sliders to frame
Reinforce tailgate
Make height adjustable rack
Make tongue box(Water pump, Batteries,...
Slide out kitchen
Propane cylinder mount
Frontrunner Gas can mounts
Frontrunner Rack
Eezi-Awn 1600 T-Top
Shovel/Axe/Hi-Lift mounts
Reciever added to tongue
Max Coupler
...
Way down the road:
Solar
Radio/Comm's
Drawer slides for the rear
Spare tire Swingout

My goal is to be able to travel the tent at a low height and sleep at 6'3"+/-, this allowing the Awning to be at an appropriate height and making the shower room off the T-Top usable.

I'll be fully documenting my build on Expedition Ops Facebook page at Expedition Ops | Facebook

 

[womacje]

Machining hubs???

I have the old stub axles so the hubs can't be swapped with a dexter to achieve my 6x5.5" stud pattern.

Heres what I was thinking about doing: Weld in the existing studs grind them flush and have a machinist drill new stud holes.

Any one tried this?

 

[womacje]

Here are some sketches of what I was thinking for design wise. Excuse the napkin sketches. (to see more images go to http://www.facebook.com/ExpeditionOps

 

[womacje]

Once, I seperated all the pieces parts of the trailer, I discovered that the main leaf were broken and the C-shackles were siezed. Thanks to Mud, I found the replacement springs but after shipping and cost they were pretty spendy. Aside from not liking the idea of trashing something that is mostly good, I also like supporting local craftsmen. So, I found a spring guy in town that was able to give me a good determination on life left in the springs and it cost me less to have him rebuild the springs and set them up for me than new springs would cost. $65 to make new mains and reassemble them as opposed to $80/spring pack from aftermarket companies. So, off they went to Randy to be reworked. I'm trying to decide how to lift the trailer, the tires will be 33" BFG AT's to match the truck on 4Runner steel wheels. That will increase the ride a bit.

I was able to pick up the wheels from a local Toyota 4WD club memeber for $40 with 32" rubber on them!!! Woohoo!

 

[womacje]

Trailer Sandblasted

I sent the trailer off to the sandblasters and got the parts back in 3 days. $300 wasn't too bad, of course I told them the only thing they needed to be careful with was the drains... guess what was bent? They knocked off $30 for the damage and I was off.

 

[womacje]

Welding sliders

PhotoGod and I grabbed steel last week and started on the sliders that are welded to the frame. These will support the Wedco cans and the propane cylinder, plus add protection to the trail from trail damage. The tires and wheels are wider, instead of extending the fenders with sheet, I figured I'd make a step surface and fender sliders as well. I'm short so adding something to walk around the trailer for loading onto the rack won't hurt either.

Here is a pic but there are more at Expedition Ops | Facebook

 

[womacje]

Adding Reciever

I swung by Northern Tool to grab 2" recievers. One for the tongue and one for the back end of the trailer frame. This should allow me to have a rear recovery point for the trailer or carry a bike rack or maybe MAYBE a motorcycle carrier.

They had an 18" tube and a 12" tube, the 18" was almost a perfect fit to reach between the two rails, this will later get 1.5"x3 14ga steel tube going diagonally to the side rails for strength and support.

 

[womacje]

Tailgate

Started cleaning the tailgate and the tub for reinforcements. Off comes the grab handles and what was left of the mounting tabs. I've decided to use 1" tube to reinforce the tailgate and create good clean hinge and seal surfaces.

 

[womacje]

Gas Lift Spring?

Does anyone have a source for 20" stroke gas lift springs? I've been trying to find them, McMaster Carr only goes up to about 15" then they get super spendy. I was going to use these in the 4 corners to lift the rack and tent, then use locking pins to support the weight of humans in the tent.
I'd love to be able to put the rack/tent as close to the top of the trailer rails as possible, then lift it to a height of 6'3" for the tall folks that travel with me. Sadly not much of a concern for me. I know the Conqueror trailers use gas lift springs for thiers as well, thats where I got the idea.

Suggestions?

 

[womacje]

I can't post to portal from my phone, so I put up a pic of the progress made this weekend on facebook, not much, but some. I have trimmed the angles off the tailgate and will begin welding them back onto the tub. PhotoGod and I have cut a 1.5"x3" section of tube at a 120 degree angle to help pull the distorted tub back into alignment and also to provide rigidity to the backside of the tub. This will be bolted onto the frame sliders.

 

[highlandercj-7]

I like the way you filled in around the fenders and extended them with the ret tubing. That's a very smooth approach.

 

[womacje]

I like the way you filled in around the fenders and extended them with the ret tubing. That's a very smooth approach.

Thanks, I've been in enough situations where being able to lean the trailer against a wall/rock would be awfully convenient(ie. Lockhart Basin Trail).
I really admire the guys that have the patience and skill to section thier fenders and widen them. I'm not a good enough fabricator to weld that much sheet metal.

Have I mentioned that I'm not as tall as I'd like to be??? Step ladder! :sombrero:

 

[97tjguzzy]

is that 1x3" tubing you used on the fenders? what thickness?

 

[womacje]

is that 1x3" tubing you used on the fenders? what thickness?

Close. I'm using 1.5"x3". Initially I was going to use 2"x3" but when I saw the material at the yard it didn't look quite right. This is 14ga, the 12ga was considerably more expensive.

 

[womacje]

Tailgate progress

Not much to see but a little progress. Welded in the vertical brace to the outside of the tub and the bolt flange to the sliders. Squared up the tailgate and trying to get the sides of the trailer straight-ish... not too easy. Ran out of welding wire, so off to spend more money! Springs are ready for pick up to, still have to decide on spring shackles, plate or C???

Keep getting an error when trying to upload pics so, you guys know the drill, they are on facebook.com/expeditionops