My Backcountry Camper Trailer Build

[R_Lefebvre]

Ok, another update... Man, the hours that's into this thing are incredible. 2-3 hours every week night, and most weekends since this thing started. Almost finished my 3rd bottle of Argon, and about 10 lbs of filler rod. :Wow1: I'm starting to see the light at the end of the tunnel.

I've got the roof fully welded on, including the load bars that will hold the Maggiolina. I welded a slight slope into the roof so that it doesn't pool anywhere. But, since I was welding mostly along the top surface of the load bars, they warped down badly. I had to use a hydraulic jack inside to stretch them back upwards. The roof is 18Ga, and working with it, I'm glad I didn't use 18Ga anywhere else. It's kinda thin. The 14Ga body will be impervious to any impacts with trees, 18Ga, not so much.

I also welded on my rear levelling jacks. When retracted, the shoe plate ends up just under the bumper. Or, I can completely remove the bottom leg if required.

 

[OlympiaFJ60]

I also welded on my rear levelling jacks. When retracted, the shoe plate ends up just under the bumper. Or, I can completely remove the bottom leg if required.

That's exactly the leveling jack I am looking for. What was your source?

Looking good, and yes, the 14ga is pretty much indestructible.

 

[R_Lefebvre]

I got it from Princess Auto, a Canadian chain of farm/automotive/surplus stores. That's a 5000lbs, which is obviously overkill, but I needed the length. It's also reasonably stiff too. That's a top wind, there are side winders available too. A side wind would have worked, but I think I'm going to make some kind of drill attachment to turn these.

 

[R_Lefebvre]

Here's the latest. Front panel is on, just have to finish welding the little side panels and build the fenders. I already have the doors all cut out, just have to sort out the hinge situation. It should all start to come together much faster now. I hope. :Wow1: I'm procrastinating on building the fenders.

I towed it around the block just for SnG and it was fine. I need to align the wheels a bit I think. The tongue weight right now is actually... close to nothing. I've got the battery in the back, and the spare tire isn't on yet which will probably make it go negative. I actually sort of planned this. When the motorbike is on the front, I don't want it to have too much tongue weight. Also, most of the cargo will be stored in the front section. I will also likely add a tongue box of some sort.

I actually find it looks less big from this angle. Of course it's a good size, but not too big. About the size of the truck which is what I was going for.

 

[sseaman]

Rob, it looks good but you need to work faster, I need more pictures to look at.

 

[Overland]

looking very good, your going to love all that storage space.

looks like your fenders will be roughly the same shape as on my trailer. the flat 'steps' infront and/or behind the fender are great storage areas. secure a propane bottle or fuel can on them. or just use them as steps for opening closing the tent. i had these cut on a laser table and bent on a cnc machine all for around $400.00 including steel.

some fender ideas for ya

 

[Root Moose]

Size looks fine. The tongue weight will work itself out as you add stuff.

I don't remember if you had something special in mind for the fenders. If you want to save a lot of time get some fenders at PA. If nothing else they can be used to skin whatever custom structure you had in mind. I did this with my utility trailer.

 

[R_Lefebvre]

Overland, the trailer is a fleetside, so no steps. I want to keep the big beast as slick as possible. Maybe it'll be less interesting looking but...

Moose: I looked at the PA fenders, but they were too narrow. I would have had to stretch them, which was going to be more work than you'd think. Also, I find the steel they are made from to be pretty bad and all the ones I've seen rust out pretty quick.

I've basically just made fenders from scratch out of 14Ga. I just about finished one side, and I'll show it later tonight I think. It actually wasn't nearly as bad as I thought, they went together quick. It was definitely easier than adapting premade fenders.

 

[Root Moose]

Yeah stretching is a waste of time. Might as well make them the way you need them at that point.

 

[dieselcruiserhead]

Rob, looking very good. I forgot to mention, TIG -- beautiful!

 

[R_Lefebvre]

Ok, so one fender is 99% finished. Hopefully I can get through the other one tomorrow night. I'm SOOOOooooo anxious to get this over with, and so is my wife. She's definitely regretting not letting me just buy the Starcraft 11RT now.

I have to make a final decision soon on the final colour. I really wanted to paint it to match the truck. I would also do the wheels in bronze to match. I just don't know how the tent will look on top. It's like a cream/ivory colour.

http://www.autohomecanada.com/file_gb/magg_safari.html

I know... obsessing about colour, but it has to look right. I am probably going to do the inside with a light tan colour. Just so it's not so dark inside the storage areas. I could do the outside tan as well. A whole "safari" them going on. Or I could go with a brown that would go well with the tan tent.

To me, just seems matching the truck is the coolest. :elkgrin:

Anyway, here's a shot of the fender I finished. Came out really well and wasn't hard to do at all. Keep in mind, every panel on this thing is hand cut with an angle grinder. Need to have steady hands for a nice clean cut. You'll also see the 20 gal water tank I picked up. I found one that fits perfectly in the frame rails. There's also just enough room behind it to squeaze in a pump or something. I'll put a little thin styrofaom under it and around the edges, and a strap over the top.

Here's a closeup of the taillights I used. I went around and around for a while. I was going to originall put the recessed oval ones in the bumper, but I thought that would weaken it too much. Then I was going to put them on the body down low, but thought that the jacks would block the view from the close side, just the wrong thing to be doing. I wanted maximum visibility, and they were also a little small. So, I picked up these standard trailer lights, with an integrated plate mount, plate light, and reverse lights which I'm sure will be nice to have. I had to mount them up high above the jacks for visibility.

 

[stomperxj]

Lookin good Rob. That's a lot of welding for sure. I must have missed it but whats the ground clearance? Did you make the rear jacks yourself?

 

[R_Lefebvre]

Thanks. Ground clearance is IIRC 18" which is more than my truck. Plus, the bottom is almost perfectly smooth for dragging. The only protrusions are the torsion beams. No, I didn't build the jacks, they are purchased. I only wish I had planned it out a little better to make them integrated.

 

[Titanpat57]

Progressing nicely...will there be room to sleep in the back on a regular basis? I like the Tow rig/Trailer color match..I thinks it's the sharpest. Of course..when I did my trailer build I had a silver Titan and before the maiden voyage got a white CX-9..oh well..******** happens. Keep up the good work:drool:

Pat

 

[R_Lefebvre]

Yes, the back will have permanent sleeping quarters for the kids. It'll be 48 by... 60? for now. So the trailer is sort of a like a teardrop in a way.