Starting my build, from jet ski to expo trailer

[jeepjunky]

Just found the Expedition Portal today. Awesome site guys/gals. I’ve wanted one of these little trailers for some time now. I decided to start the build today! The plan is to build it with little to no cost. Now I know what you are thinking, little to no cost??? Yes I will spend money, there is no way around it, I just want to see how inexpensive I can go...without it looking like it.
So far I think I’m off to a good start, I got a trailer FREE! It’s a little smaller than I wanted but it was FREE. It was a single Jet Ski trailer. The box area measures 36" long x44" wide. Yep it’s small! I’m planning on using a standard sized Colman 2 person tent (about $40.00) they measure 5x7. I just need to build a box...time to go to Menards. I’ve got to run my daughter to an activity, so Ill post a pick of the trailer when I get
Cost to date:
Trailer - FREE
Trailer lights - 19.99
License - 29.00 but really I would have to do that anyway so it don’t count

 

[jeepjunky]

Ok here is a pic of what I'm starting with. I spent about an hour in Menards and was fairly disappointed. One option was to use wood. But I don’t want to worry about rot and water damage. So I looked at composite decking; it’s too expensive and I don’t like the wood grain look. Next I looked at gorilla racks frames; they are close to the right size only 17" deep I'm wanting 24", powder coated, and inexpensive ($30-40) to build the two side walls. I’ll wait till tomorrow to price bulk metal before I commit to anything. Any ideas?

 

[skersfan]

I am not sure of how trail worthy the base unit it. Need more pictures of the actual frame. Awfully long tongue and does not look to be 2.5x2.5 reciever material. Show us more.

 

[Mark Harley]

Head to the Tractor supply or Farm and fleet to see what boxes they sell
or order the sheet steel and bend it yourself. I would shorten the tongue a couple inches too.
It looks like a nice start. junk yards and metal recyclers are our friends.
Check there for build ideas.

 

[jeepjunky]

Well I spent the last couple of days looking at things I could "convert" to work. Then I priced the steel to build what "WILL" work. I just spent $84.54 on 3- 20'x1"x1"x1/8" square tube and 1- 20'x1"x1"x1/8" angle. That price is for all the metal + tax AND delivery to the house:wings: That will build the frame. I will still have to skin it and put a floor in it. As soon as its delvered and I start fabbing Ill take and post pics.
Cost to date:
Trailer - FREE
Trailer lights - $19.99
metal for frame - $84.54

Total - $104.53

 

[jeepjunky]

I must ask, when I set the box on my trailer how should I center it? Ive modified my original plans, itd going to be 48" deep instead of the 36" that the trailer is. So should I have the box overhang the trailer 1' per end (front and back) thus centering the axle to the box. Or, am I ok to have the box overhang the front 2' and the rear end with the trailer frame?
Thanks

 

[jeepjunky]

So I got the frame work and tailgate built. 24" is a little taller than I expected. But it will work fine. I still need to finish the hinges for the tailgate and the tailgate chains. I also need to put the floor and side skins on/in. any ideas on how long or short I should make the tongue?

 

[jeepjunky]

itd going to be 48" deep instead of the 36" that the trailer is. So should I have the box overhang the trailer 1' per end (front and back) thus centering the axle to the box. Or, am I ok to have the box overhang the front 2' and the rear end with the trailer frame?
Thanks

Ok so I cant do simple math. Well actually I can. the trailer is 36" deep, When I posted this I was planning on making the box 60" not 48" thus the 2' overhang question. However when I did my measurements I got 48" stuck in my head. So my trailer is now 48." The idea was that the tent being 60" wide I would make the trailer 60" deep. So since I screwed up my measurement Ill need to figure out how to origomy my tent base to fit the lid.

 

[jeepjunky]

Well all I did today was drag the trailer around and get bids for the 16gauge walls. I was supposed to get a call back today for the final bid, I think it came out to $40.00 for the metal and $8.00 to cut it but I don't know what the programming fee is for the CNC cutter. My other bid was for the same metal but to shear it...$160.00...ouch...funny both places buy there metal from the same supplier.
I did prime and paint the trailer today. Nothing fancy just semi-gloss black. I bought 2 cans of paint, and had 1/2can of paint and primer left-over from another project.
Cost to date:
Trailer - FREE
Trailer lights - $19.99
Metal for frame - $84.54
Paint - $7.54

Total - $112.07

 

[bunger]

You're doing good so far at keeping the costs down.
I have spent about $500 on my "free" trailer so far and I'm only about half done with the build.

Good luck

 

[Mark Harley]

Look for trade schools in the area.
They have metal fab classes and have then cut your metal to size
You can donate or offer a Pizza party to the class
Cheaper than a shop would do.

I like how it is going. Keep us posted.

 

[Dirtytires]

Welcome Abroad.

 

[jeepjunky]

A little more done today...means more money spent...o-well. I rattle-can painted the whole thing black. I also added some support the rear corners, made tailgate stops and cut the tailgate down 1/4". As for the money, not much, $37.00 for green treated 3/4 4x8 plywood. Store even cut it down for me. Now I just need to figure out how to Origami the second piece for the lid. It is 50"x48". The tent is 60"x80"...or84” I’m thinking about buying 2- 6"x3/4" x 8' boards and hinging them on the 48" side. Also buying a 1/2 sheet of ply to get my length. Confused yet...
I’ll start over; mount the 48x50 ply on the lid of the trailer. Hinge a 48x34". This way when I open it will be 48x84. I’m still 12" too narrow for the tent. So If I take 2 6" wide boards hinged to the 48" side It SHOULD work. But it’s going to take a lot of hinges to make it work.
If I buy ply to make it a full 2-piece tent base I’m up to $74.00 + hinges. If I buy the 1/2 sheet $23 + 5or6 for the boards...then $?? for the hinges.
Remember I’m going cheep and functional. Also any thoughts about skinning this in wood vs metal? My metal guy was guessing $40 for the 16gauge and $24 for cutting it, and $45 for programming. So $109 for metal, I wonder if it would look good (requirement) if I skinned it in 1/4" ply or tongue-n-grove...I’m guessing I could buy enough wood for less than the metal. Again your thoughts?
Cost to date:
Trailer - FREE
Trailer lights - $19.99
Metal for frame - $84.54
Paint - $7.54
Lumber - $37.00

Total - $149.07

 

[jeepjunky]

I got quite a-bit done today. I found some steel in my storage shed I cabbaged onto when doing a clean-up project. So I cut it down, and wouldn’t you know there was enough to make all 4 sides of the box. I’ll need to sand the surface rust off the sides, finish stitch welding the sides and cleaning the welds and cuts. Also this is repurposed metal, so I’ll need to cut the old junk off that had been welded on. Also there are some minor imperfections I’ll need to live with. But it was FREE! I hope to figure out the roof dilemma tomorrow.

Cost to date:
Trailer - FREE
Trailer lights - $19.99
Metal for frame - $84.54
Paint - $7.54
Lumber - $37.00
steel for sides - FREE
Shop materials - 6.00

Total - $155.07

 

[jeepjunky]

got a little more done, cut the lid down, bought hinges, removed box and stich welded the bottom skin. re-attaced the box and mounted the lid. All thats left for the year is prep for paint, paint, buld the hinged tent base, and stablizer jacks.
When I mount the front stabilizers do I mount them on the front of the box, or out on the tounge?
Cost to date:
Trailer - FREE
Trailer lights - $19.99
Metal for frame - $84.54
Paint - $7.54
Lumber - $37.00
steel for sides - FREE
Shop materials - $13.93
Hinges - $7.99
Misc parts - 3.96

Total - $176.34