Zelix Homemade Trailer Build

[JeepN95YJ]

I believe you can weld huge diff guards onto an axle without warping the housing.

 

[ntsqd]

[drift]It moves when you weld on something like that. Weld bead always shrink. The $64 question is if it moves enough to matter. Too many variables involved to make a blanket prediction.[/drift]

 

[Zelix]

Thanks for the replies. I actually spent some time on the trailer yesterday. It was nice and cool outside.

Here's the result of the cut, strectch, and reweld. I used the tailgate for leverage. I put a 1/8" th. metal on the one side and used an old screwdriver to wedge the welding side. It isn't perfect, but I'll live with it as it is.

I also got the latches welded on. It looks a bit beefy...but I like it that way. :sombrero:

I decided to pull the trailer out from under the 'tent' work area and clean up a bit so I could move around. I had the idea "lets hook it up to the old explorer". I will mostly pull it with my jeep... but I'm thinking that the explorer is good for small fishing and camping trips. I can actually sleep in the explorer.

One thing I noticed is that the axle brackets are off approx. 1/4" so the one tire is closer to the frame than the other. I was a bit pissT as it should be even since It wasn't my fab. work.... I couldn't believe that it came from teh factory like that. Oh well... I have spacers on the way.

I'm going to make some [removable] chains with hooks to hold the tailgate horizontal. It would make a great cooking or sitting platform.

What's left?

• end plates on the tubes
• front edge angle to fasten the wood deck too
• cut down and fasten fenders.
• fabricate something to fasten the lights too.
• weld on all the tie down D-rings
• nut and bolt tighten check
• grind and smooth ~ check all welds
• prep and paint
• hook up lights
• put on wooden deck

Did I miss anything?
I'm really getting excited about this project now. The weather is changing and cooler.... feels great outside and no mosquitoes.

 

[toyota_jon]

good job on your first major build. watch out though it gets addicting, pretty soon you'll be looking around and figuring out what else you "need" to build. :sombrero:

 

[Zelix]

good job on your first major build. watch out though it gets addicting, pretty soon you'll be looking around and figuring out what else you "need" to build. :sombrero:

Thanks for the post.

I think I already have the "addiction"...:sombrero:

The list of things I want to make:
a luggage carrier for the receiver hitch
a tent for the trailer
small yakitori camp grill
camp kitchen box

 

[Zelix]

Yay

I was pissT this weekend. I tried to put on the spacers and they wouldn't fit over the hubs. I have to send them back for refund. So I sulked and moaned about it for a while... I thought what can I do?

I bit the bullet. I took a grinder to the axle that was actually 1/2" off. I got the seat thingys and repositioned them and welded them in the correct place. I got the axle bolted on and the tires on. It looks alot better now. Theres a good bit of room. Anyone know how much room is needed between a tire and the frame?

Here's a couple of pictures of the axle before the fix.

 

[The Adam Blaster]

Anyone know how much room is needed between a tire and the frame?

Laterally, I'd say 2" - but I've never built a trailer myself. Just observed a few in my day.
You could go to an RV place and look at their trailers to get an idea.
I actually think most tailers come with the tires closer than 2" to the frame, but leaving a bit extra space you can upsize your tires if the need/desire comes up in the future. And that might be the critical issue -- how big are your tires?

 

['05TJLWBRUBY]

I was pissT this weekend. I tried to put on the spacers and they wouldn't fit over the hubs. I have to send them back for refund. So I sulked and moaned about it for a while... I thought what can I do?

I'm sorry I saw this so late. Not to rub salt in an open wound, but that's exactly what I was talking about in my build thread, and why I brought it up-they don't fit, and won't fit no matter how you try. Sorry you had to find out the hard way.

If you still want spacers, get ahold of Jeremy at JT's-he's just down the road from me in Cashmere WA, has plenty in stock and is great to work with. Standard Jeep TJ 5x4.5 pattern that will fit your standard Dexter hub pattern and the center bore is plenty large enough to fit over the Dexter hub drum, even with electric brakes like I have on mine. Here's his site:


http://www.justdifferentials.com/index.php?main_page=product_info&cPath=467&products_id=2163

I'm not sure I linked the exact spacer there-he has several different ones, including cruisers and 8 lug chevs. For the Jeeps, which will fit the Dexter axles, he has 1.25", 1.5" and 2" to buy the clearance you may need to get it out away from the frame more which will help with your cutting/welding you're after now. Check my build thread for more info, I don't remember the specifics. Haven't updated it in a while as I've been working so much. I'm off now for two weeks of elk hunting and wheeling so no trailer work for a while yet. Oh, these are a bit cheaper than Spydertrax too. For what it's worth, I have over 30,000 on my Spydertrax on the Jeep with great results. I'd have used them if they would have fit, but as you found out, they just won't work. Jeremy's will, and do. They're a great alternative.

Best of Luck,

Mike

 

[Zelix]

Laterally, I'd say 2" - but I've never built a trailer myself. Just observed a few in my day.
You could go to an RV place and look at their trailers to get an idea.
I actually think most tailers come with the tires closer than 2" to the frame, but leaving a bit extra space you can upsize your tires if the need/desire comes up in the future. And that might be the critical issue -- how big are your tires?

I'm not sure how big they are. The rims are from a ford explorer...They came with used tires on them. I got them cheep.

I was talking this over with some pals here. I decided to just try out driving with the clearance I have now. If I notice wear I'll do something different.

I'm sorry I saw this so late. Not to rub salt in an open wound, but that's exactly what I was talking about in my build thread, and why I brought it up-they don't fit, and won't fit no matter how you try. Sorry you had to find out the hard way.

If you still want spacers, get ahold of Jeremy at JT's-he's just down the road from me in Cashmere WA, has plenty in stock and is great to work with. Standard Jeep TJ 5x4.5 pattern that will fit your standard Dexter hub pattern and the center bore is plenty large enough to fit over the Dexter hub drum, even with electric brakes like I have on mine. Here's his site:


http://www.justdifferentials.com/index.php?main_page=product_info&cPath=467&products_id=2163

I'm not sure I linked the exact spacer there-he has several different ones, including cruisers and 8 lug chevs. For the Jeeps, which will fit the Dexter axles, he has 1.25", 1.5" and 2" to buy the clearance you may need to get it out away from the frame more which will help with your cutting/welding you're after now. Check my build thread for more info, I don't remember the specifics. Haven't updated it in a while as I've been working so much. I'm off now for two weeks of elk hunting and wheeling so no trailer work for a while yet. Oh, these are a bit cheaper than Spydertrax too. For what it's worth, I have over 30,000 on my Spydertrax on the Jeep with great results. I'd have used them if they would have fit, but as you found out, they just won't work. Jeremy's will, and do. They're a great alternative.

Best of Luck,

Mike

Thanks for the reply. I still haven't returned the spacers. I might just put'em on my jeep. The whole make lemonade thing.

I'm sorry I didn't check your build out before hand and save myself some misery. I tell ya there's just soo much great info in this one trailer sub forum it's hard to remember it all. :sombrero:


I've got a good 1/4~1/2 inch clearance now on each side. I think that should be good since the springs are really heavy duty...

I'll check out the link and bookmark it in case I need them. I'm thinking of running as is for now. The used rims I bought have some old used tires on them. It'll be no lost to ruin them. Unless anyone thinks it's a recipe for disaster.

BTW: I cut the fenders down 5" each side [ like box rocket did his]... They are looking good. I have to devise a way to mount them now. I'm getting "trailer fever" You know that fever you get towards the end of a build. I'm really having to slow down and think of things before I ride off on a horse and ruin things.

My "to do" list

• mount fenders
• ledge angle for wood deck [still haven't done that]
• devise a way to mount the lights & secure the wiring
• mount the chains/hooks
• prep, prime, paint
• install wood deck

 

[Zelix]

Worked on the trailer this weekend some. I got the fenders mounted, the tiedowns mounted and a few welds tightened up. I took it out on a shakedown run. I have to get spacers that fit, no question about it. I'll take '05TJLWBRUBY's suggestion and order a set of the spacers.

anyway heres a few pictures so far:

I drilled holes and welded some nuts in the frame to mount the fenders.

Here's the ole girl hooked up to the JEEP. I couldn't resist trying it out.
it pulled wonderfully.... I almost forget it was back there. heh

Here's a shot with the D-ring tie downs installed.

I'll order the spacers in 2 minutes. When they get here I'll get'em installed. I'll have all the other items cleaned up and ready. I would love to paint this weekend..... I doubt I'll get that far.

 

[Box Rocket]

Coming along nicely. Like the tiedowns.

 

[Zelix]

Coming along nicely. Like the tiedowns.

Thanks.... I thought they might come in handy... and they just look cool to me. haha


Well I'm one happy camper, pals.... The spacers that '05TJLWBRUBY recommended work. They fit like butter! Thanks again man... I was sweating what I was gonna do.

Last nite I installed the spacers and I worked on the tailgate some. I'm officially at the clean up and tweek stage. I hope I can get it all fine tuned by this weekend. I'd love to paint Saturday. Wish me luck as I'm on the final stretch.:wings:

 

[Zelix]

The trailer is officially done [with exceptions to mods] 11-17-09

Well it's done. I only have a couple of small things left. finish wiring up the lights, install chains for the tailgate, and bolt down the wood deck. I called the tag office and got the info on getting registered and tagged up...I'll do that tomorrow [if I can get the lights wired and they work properly]

Here's some pictures:

I used wood decking... I have to get those bolted down tonite as well.

I'm pretty pleased with how it turned out. One thing I'm not 100% happy with is the metal sheeting. It wasn't cut out as good as it could have been. It was my first time cutting metal sheeting.... Let's just say it was a learning experience. I might replace it all later on. For now I'll just use and abuse the trailer hehe... I'll get an idea of what I need to replace~modify after some usage.

Stay tuned.... next pictures will be of the ole girl loaded for camping.

 

[Box Rocket]

Looks like it will be a good little trailer for you. Nice job.

 

[Zelix]

Looks like it will be a good little trailer for you. Nice job.

Thanks for the post. I'm really happy with how it turned out... My daughter is already asking when we're going camping. heh