Thinking about scratch building a trailer- am I crazy?

[zimm17]

I have a Casita travel trailer, but I'm thinking about getting a small off-road type trailer for going to rougher camping areas or even when I'm cub scouting with my boys. It won't get pulled on the trails, just to them.

I'm newly retired from the Navy, I have a 2 car garage, a new Millermatic 211 welder, grinder, and a chop saw. I can't afford an already built off-road trailer so I'm thinking about building one. How hard is it really to do? I'm pretty confident in my MIG welding skills- at least when doing 1/4" thick plates. I haven't tried sheet metal yet.

I'm not much for sketching plans or playing with sketch-up. Is there a good source for plans? I think it would really help to know ahead of time what size Dexter axle to get, tubing sizes to order, etc. Is a 4x6 box the standard?

I'm thinking a 2x3 ladder frame and either a box with side storage (like AT's) or a M416 type. Side storage boxes could be already made tool boxes for work trucks, or something like that. It will have a RTT so I need a tailgate or door for rear access.

How much of a budget would I be looking at for all the steel and an axle?

Once the box and lid are done and I have a towable trailer, then I can play with building onboard systems, etc.

I figure a deep cycle battery and onboard charger. Probably solar at some point. I already have an ARB fridge- but that can stay in the vehicle. I have a Partner stove, so maybe a 5lb propane bottle for it. Water tank and pump for doing dishes.

Or should I just beef up a tiny enclosed cargo trailer with bigger tires and a lift?

 

[john61ct]

Do the sketchup for size & functional layout

Pay an engineer for detailed plans with materials list

build off that

Won't save money but will be a much more robust result.

TNTTT.com for ideas

also this

Sawtooth Unlimited - Off Road Pop Top Camper Trailer https://expeditionportal.com/forum/threads/sawtooth-unlimited-off-road-pop-top-camper-trailer.183743

 

[zimm17]

I'm thinking much more simple. A cargo box to hold camping gear. RTT on top. I'm sure I can build the frame. It looks like keeping it all straight and square is the hardest part. If I could find an arrangement of truck tool boxes that would work, it would take away a considerable amount of fabrication. Maybe a pair of chest toolboxes sitting lengthwise on the trailer frame, back to back and another across the back. Or a larger 4' wide box that would be the main body of trailer and a pair of smaller toolboxes bolted to the sides like an Adventure Horizon trailer. Then built a raisable frame for the RTT.

 

[OverlandNA]

https://compactcampingstore.com/col...nstruction-manual-diy-compact-camping-trailer

Explorer Box Trailer Collection

 

[old_CWO]

should I just beef up a tiny enclosed cargo trailer with bigger tires and a lift?

Yes, this sounds like what you are describing. 4x6 cargo trailers are common and affordable even brand new. That gets you 80-90% done for around $1500. You will pay more than that for materials and from the application you explain this trailer doesn't need to be Rubicon ready. Do a spring over axle conversion, slap a slightly bigger tire on it and go camping. Better to be in the woods with the boys than in the garage with the welder...

 

[NatersXJ6]

Take the boys into the garage and teach them to build a trailer. It isn’t hard. Make sure the frame is square and true and the axle is perpendicular to the frame. Hard to get much wrong.

Stick with the toolboxes over the 416 style if you haven’t done it before. Bending the sheet for the 416 will either be pricey or difficult and adds project complexity.

 

[IdaSHO]

Go for it.

The biggest struggle for a DIYer is keeping weight down.
So my advice is to consider your designs and choice of materials carefully, and always think about weight.

 

[Louisd75]

I have a Casita travel trailer, but I'm thinking about getting a small off-road type trailer for going to rougher camping areas or even when I'm cub scouting with my boys. It won't get pulled on the trails, just to them.

I'm newly retired from the Navy, I have a 2 car garage, a new Millermatic 211 welder, grinder, and a chop saw. I can't afford an already built off-road trailer so I'm thinking about building one. How hard is it really to do? I'm pretty confident in my MIG welding skills- at least when doing 1/4" thick plates. I haven't tried sheet metal yet.

I'm not much for sketching plans or playing with sketch-up. Is there a good source for plans? I think it would really help to know ahead of time what size Dexter axle to get, tubing sizes to order, etc. Is a 4x6 box the standard?

I'm thinking a 2x3 ladder frame and either a box with side storage (like AT's) or a M416 type. Side storage boxes could be already made tool boxes for work trucks, or something like that. It will have a RTT so I need a tailgate or door for rear access.

How much of a budget would I be looking at for all the steel and an axle?

Once the box and lid are done and I have a towable trailer, then I can play with building onboard systems, etc.

I figure a deep cycle battery and onboard charger. Probably solar at some point. I already have an ARB fridge- but that can stay in the vehicle. I have a Partner stove, so maybe a 5lb propane bottle for it. Water tank and pump for doing dishes.

Or should I just beef up a tiny enclosed cargo trailer with bigger tires and a lift?

Fastest and easiest route is to beef up a prebuilt trailer. Building is a fun project that I've been able to involve the whole family in. Tnttt.com was posted before, you may also take a look at TVenturing.com for ideas as well. There are companies such as Dinoot that sell kits to speed the build process along, depending on how much fab work you want to do.

 

[ITTOG]

Tongue length is what impacts backing up the most. Make it short and you have to go much slower.

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[ITTOG]

I'd start with a manufactured trailer like this. Usually about $1500.00. All welded, all legal, lights, hitch, registration ready.
This is a 5x10 Mirage, and I flipped the axle.

View attachment 514533

Then just build yer box.

Mine has a full double bed inside, more like a teardrop trailer, kitchen on the back. 20" deep storage on the nose.
I hate tents !! With this, I park, roll in, go to sleep.... almost anywhere, zero setup.
In the morning if is raining, roll out, drive away.

View attachment 514534

Mine disassembles but you could build/weld a slide in camper box
Heres one someone else is building

View attachment 514536

I am planning to convert my cargo trailer into a slide off. Will probably have to wait until next year to begin though. Toughest part is figuring out how to get it on and off the trailer.

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[Brianj5600]

Figure out what RTT you want and consider the folded size into the size box you build. My tent is 47"x76"x11" so my box is 48"x80"x33". Putting it on a 48"x72" would mean the tent would hang off the top of the trailer. Nothing really wrong with that, but I thought it would look odd. So far I've spent $375 on tubing, $335 on Dexter 3500lb axle with brakes, $80 on hinges and latches, $35 on pick-a-part leaf springs from Colorado Pick up, about $100 on leaf mounting brackets, $30 on lights and $40 on trailer side 7 way plug and harness. I expect to spend $300-$400 on skinning it.

 

[ITTOG]

A cargo trailer is often engineered with consideration to the strength of the cargo box. A deck trailer, all else equal, will have a stronger frame since the box contibutes nothing. Quite possible all will work if as a slide in camper you are much lighter than the cargo box trailer was designed for.

Mine is beefed up more than a flatbed because I take it off roading primarily. It is all 2x4 tube framing on 16" centers. So not an issue. Cargo box is beefed up as well.

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[ITTOG]

Wrong, it is distance from the ball to the axle. a 60" tongue, 12" from the axle will reverse identical to a 36" tongue 36" from the axle.

Hmm, I thought I added "and axle placement" but obviously not. I was trying to clarify because you just had trailer length which has nothing to do with it unless you put the axle at the end of the trailer. Thanks for catching my mistake.

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[FosterWV]

I vote scratch build! It's built your way and you can be proud it's yours, although the 4x6 cargo trailer is a great starter idea!

 

[mikeyb1976]

I vote scratch build! It's built your way and you can be proud it's yours, although the 4x6 cargo trailer is a great starter idea!

View attachment 514577

I vote build as well, if you have the basic skills. It becomes an adventure unto itself.

You can order virtually everything online. I did a rough price list of building my own (similar to this ^^^ - which, btw, the kayak holders probably cost more than the steel for that trailer ) and it came at well under $1000. If I add human comforts like a water heater and tent heater, then the price starts creeping up. But I'd still be nowhere near $$$ spent on the Smittybilt trailer (which I consider the bare-bones option).

If you have a little bit of mechanical knowledge and research ability, there's no reason why one couldn't build their own trailer.