"TrailTop" modular trailer topper building components

[klb67]

I don't recall the interface between the sides and the front and rear panels. Can you leave front, rear and top on and remove the side panels? If so, I would be more likely to swap out cargo panels for camper panels. If not, I probably stick with the camper panels and possibly use a thin sheet of plywood over the windows when hauling cargo to protect the windows, rather than lift off the top to swap out side panels. I like the front hatch.

 

[southpier]

....keep the side panels solid for cargo use and build a separate set of side panels for camping use. Each side panel costs less than $20 to make, and since they bolt in place so swapping side panels is easy so it's not a big deal to have a multiple sets of side panels for different uses.

I imagine one set or the other would require water resistance so "swap-ability" might include a gasketing material (thinking once they come into mainstream availability through a licensed vendor) and their cost at that stage would certainly well exceed $20.

 

[jscherb]

I don't recall the interface between the sides and the front and rear panels. Can you leave front, rear and top on and remove the side panels? If so, I would be more likely to swap out cargo panels for camper panels. If not, I probably stick with the camper panels and possibly use a thin sheet of plywood over the windows when hauling cargo to protect the windows, rather than lift off the top to swap out side panels. I like the front hatch.

Yes, it can be used with only the ends/lid without the hard side panels. If you still wanted the TJ soft top retainer rail you'd swap the full hard side panel for simple top bars with the retailer rails attached.

For running without the hard sides I'm thinking about doing roll-up soft sides - they would be very handy for loading/unloading cargo. Here are a couple of concept drawings... soft sides rolled up:

Soft sides rolled down, shown with soft windows sewn in. Or could just do plain canvas with no windows.

I've done roll-up soft sides before, my LJ Safari Cab has both roll-up soft sides and a soft barn door in the back. The trailer sides would be pretty much the same as the ones on the LJ in most details except maybe smaller windows (or no windows).

 

[jscherb]

I imagine one set or the other would require water resistance so "swap-ability" might include a gasketing material (thinking once they come into mainstream availability through a licensed vendor) and their cost at that stage would certainly well exceed $20.

Side panels for this design wouldn't cost any more if the TrailTop system became a commercial product - they're DIY built and don't use any fiberglass TrailTop parts, just a piece of plywood with a little framing and a few pieces of weatherstrip.

 

[jscherb]

I'm thinking about windows in the sides. I've got several pairs of slider windows on hand that could be used. In these first photos I'm holding a 24" long window against the side. It's about 16" tall.

This next window is also about 16" tall, but it's 36" long. It's actually a preproduction window from a JK 2dr factory hardtop slider window kit that just went into production.

I've got a pair of each of the above windows so I could use either (or both).

Any thoughts on these or any other window ideas?

 

[Space Wrangler]

Depends what window you are planning to use for the hatch .If you had 3 @ 36" that would look the best . 2 For the sides and one for the hatch

 

[jscherb]

Someone suggested:

It looks from the photo that you could use two of the 36's on each side. Lots of light and ventilation in the event it doubled as a camper. Although if I read your post correctly you only have two of those.

That's correct, I only have two of the 36" windows on hand, but I do have a production set coming my way (the two I have are preproduction). Seems a shame to use all four of the custom-fit 2-dr JK windows on this project, but it's pretty likely I could find 4 windows at the RV surplus outlets I mentioned, so if I decide 4 windows is the best way to go I probably wouldn't have to use all of my custom JK hardtop windows.

The side panel is just under 7' long, so two 36's fit nicely with just under 4" on each end and between them. Here's what 2 36" x 16" windows would look like (I've also drawn the lid on top).

For comparison, a single 36" and single 24"...

 

[southpier]

for what it's worth, a small window would allow some privacy and view/ ventilation. the larger or doubles may expose too much. (yes, curtains could be incorporated)

 

[jscherb]

for what it's worth, a small window would allow some privacy and view/ ventilation. the larger or doubles may expose too much. (yes, curtains could be incorporated)

I agree the double windows is too much. I'm leaning towards a single 24" window in each side.

 

[jscherb]

Another option that might be useful is putting one window in each side plus a cargo hatch with a storage compartment behind it. The compartment could store tools, trail gear, kitchen supplies (maybe a kitchen work surface would be set up under it).

I've got two hatches that are the same size as the 24" windows so I could do one 24" window on each side and one 24" hatch with a compartment.

 

[5th]

Just got caught up. It's been a great read thus far. Your designs and builds are a thing of beauty, thanks for sharing.

 

[jscherb]

Just got caught up. It's been a great read thus far. Your designs and builds are a thing of beauty, thanks for sharing.

Thank you very much for the nice comments.

 

[jscherb]

Travel to the SEMA Show and a camping trip in Death Valley will prevent me from doing any more work on this project for the next few weeks, but here's what's left to do when I get back:

- Make the rear door. I'll modify some off-the-shelf hinges to be lift-off so the door can be easily removed, and I'll use the window I showed a photo of earlier. I'm ordering a locking paddle latch for the door.

- I need to decide on any side windows/front window or front hatch and install them. I could use the windows I posted photos of the other day, but also on the way back from out west I plan to stop at my favorite RV surplus places in the Elkhart, Indiana area.

- Glue the panels together. So far I've assembled the panels with screws so that any final adjustments could be made to the fit. To finalize the panels I'll disassemble them and reassemble them with glue - waterproof carpenter's glue for the wood-to-wood joints and epoxy for the wood-to-fiberglass joints.

- Put a finish on the panels. I'll use polyurethane varnish on the inside, and acrylic deck coating for the exterior. I used an acrylic deck coating on the lid I made with TrailTop parts 3 years ago, and it still looks as good as new, so I'll use the same type of coating.

This time I'll use smooth Behr DeckOver from Home Depot: http://www.behr.com/consumer/produc...-cleaners-and-strippers/behr-premium-deckover. Haven't decided on the color yet, if anyone wants to visit the link, check out the colors and recommend something I'm very open to suggestions. I have no plans to change the yellow of the tub, but I'd consider recoating the lid if that's works out best with the available colors.

There are a few more small details to finish, but the list above is all the big stuff. I'll get back on the project when I get back from the trip.

I may post concept drawings/photos as I have ideas while on the trip, but actual work won't resume until I get back.

 

[jscherb]

One more idea before I go... in addition to the hard lid/tilt-up camper top made from TrailTop parts I've got a snap-on soft tonneau for this trailer:

Because I've made the top edge of the topper match the top edge of the Jeep trailer, the tonneau will fit on it the same way it fits on the base trailer so if I ever needed to carry cargo that might be too tall to fit inside under the roof, I could swap the hard roof for the tonneau. Here's the tonneau setting on the work-in-progress topper:

 

[jscherb]

I'm on my way back from my SEMA and Death Valley trip so I'll be getting back to the topper project shortly. I've been thinking about the finish I'll put on it and instead of a single color I'm thinking maybe a mural would be fun, perhaps something like this?: https://www.ebay.com/itm/Tropical-S...m3f5ae7282f:m:m5ZGb95mC4uCX4UnHsIvvMw&vxp=mtr

A simulation:

This mural goes well with the safety yellow tub, but there are many others available so I'll do a little searching to see what else might look good.