My No-Weld Trailer project - Sort of

[billiebob]

Taking everything apart and starting the paint process. I will paint everything inside and out, then once all is put together I will do a rubber coating on the bottom
View attachment 609389

I love guys who don't rush the process. Set the plan and "Git 'er Done"

At this point it would be simple to cut a bunch of crush sleeves. And slide them is as you reassemble. Not every bolt, but key bolts at every plate. No need for a tight fit, as you torque the bolt they will become tight. Use something like needle nose vise grips to feed them in.

 

[bricke]

I am resuscitating this thread as there were developments, the project took an unexpected stop for a year or so but now it's going stronger than ever, here are some pics to catch up:

 

[bricke]

Needed a drill press, craiglist to the rescue!!
Got 2 of these Japanese made presses, a standalone and a bench top, needed some TLC, I converted the small one to DC

 

[bricke]

During my planning phase I badly miscalculated the fender mounts, live and learn I guess.
Luckily I am a decent garage welder - frame will still be bolt-on but fenders are now welded to the side tubes

Same for the main box, it will be welded together and bolted to the frame

 

[bricke]

Went to the DMV to get it registered.
Frame with suspension and wheels, weights 650lbs as seen in picture:

 

[bricke]

Box was already in progress, had to change the design a couple of times and a couple more from this picture as well. My grinding skills are improving that's for sure:

 

[bricke]

Since I last posted here I had switched from MIG to TIG (for other projects), I had to wait until I was done with the majority of the welding work on the trailer before switching tanks so that slowed me down.
Then I changed my mind and had to do a bunch of weld work on the trailer, this time with my TIG, run out of gas mid-project, went and got some flux core and there has been some learning curve but much better than doing everything with the TIG.

 

[bricke]

Back door and side doors up:

Will have to remove that latch but at the time I didn't know yet

Adding a support tube for the spare tire carrier:

And side door:

Gap is an optical illusion, it's not that wide in reality even if I have to say, it's not perfectly square - weirdly enough, the outer frame is not, the door is perfectly square!!!

 

[bricke]

Welding the tire carrier:

Tires need to be replaced and the new ones will match my truck so will be a little bigger, hence the gap

 

[bricke]

Paint and RTT!

 

[bricke]

Testing the RTT:

Side panels and front panel went up, I have used 0.1in diamond plate alu for this and taped via 3M VHB tape, I am addicted to that stuff

Unfortunately ordering a top panel of the right size is way too expensive (shipping alone is ~400$) so, modified the top to hold 2 panel and still be waterproof:

 

[bricke]

Sealing the MDF panels for the interior of the side doors, going back I would not have used MDF will update in the future if it gives me issues for now I have sealed it and painted it, will be sandwiched between 2 metal panels anyway.

Fitting the top panel:

And gluing it down - 3M VHB tape used, man I love this stuff, see the MDF inside the side door as well

 

[bricke]

All glued down and installed!!

On the road!!

 

[bricke]

Lots of details still missing, the interior is a plain box and will probably stay that way for a few more months until we figure out what works for us, flooring is coming soon and I still have to make the rear door fold-out table, I have a 1/2in plywood leftover so I am going to use it - tires will need replacing to match my truck ones but other than that, it's ready to camp!

 

[pigsammy]

Well, I think you can call that a success!

The trailer looks great, there are always things one learns on a prototype that change on future builds. Sometimes technique, sometimes materials. I usually see an awesome idea somewhere right after I finished material cuts or welding something up!

With the larger bolts you have, is it possible that carriage head bolts would work well enough in your open floor spaces? If they can be torqued to your specs, they would give a much smoother surface.

Love the build, now we need in-use photos and a synopsis of your next project!