post #1 of Old 03-29-2012, 08:33 PM Thread Starter
bfr
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homebrew expedition trailer

I want to spend more time traveling/ camping, but I don't want to give up my TJ so I decided a trailer was in order. This trailer is only meant for camping/ over landing. It will never haul a lawn mower or sheet of drywall, instead I want it to meet the following requirements.
1. It must be able to survive anything my jeep can pull it through.
2. It must be able to carry provisions for 3 people for 7 days.
3. It must have a self contained kitchen and potable water supply w/ hot and cold water.
4. It's electrical system should have a 72+ hour reserve while powering an ARB freezer.
5. It must weigh less than 1200 lbs loaded.
6. It must have an extendable tongue w/multi axis hitch
7. It must have a rear receiver hitch ( recovery point / bike carrier mount).
8. It must have brakes.


9. It must look like it belongs behind a jeep

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post #2 of Old 03-29-2012, 08:46 PM Thread Starter
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The inspiration...
WWII 1/4 ton trailer I used to own. Modifying this to meet my requirements would have been as much if not more work than building for scratch, so I sold it. Also, the TJ is so much bigger than the MB / GPW that I can build my trailer a little bigger and it still look "right".
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post #3 of Old 03-29-2012, 09:11 PM Thread Starter
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The Frame:
I found two 20' sticks of 1/8" wall 2"x4" steel tubing for sale close by at a good price so I bought it. A little quality time with my newly acquired second hand harbor freight band saw and those tubes were no longer 20' long.

All of angles were cut with the hf saw as well.

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post #4 of Old 03-29-2012, 09:26 PM Thread Starter
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I used a friend's plasma cutter to make holes in the front and rear faces if the frame and then welded .250 wall 2.5"x2.5" (receiver) tube in the rear and 3/16 wall 3"x3" tubing in the front (will allow the tongue to telescope)
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post #5 of Old 03-29-2012, 09:30 PM Thread Starter
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Suspension:
I am using the springs and hangers from an early 90's Toyota 2wd pickup. It the pic below I am testing the ride height/ shackle placement using bags of concrete for ballast.
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post #6 of Old 03-29-2012, 09:33 PM
ryan22ddd
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Looking good dude. Assuming you'll get that hitch up a tad higher and use a pintle hook, but I'll shut up and watch. :opcorn::
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post #7 of Old 03-29-2012, 09:44 PM Thread Starter
bfr
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Quote:
Originally Posted by ryan22ddd
Looking good dude. Assuming you'll get that hitch up a tad higher and use a pintle hook, but I'll shut up and watch. :opcorn::
The hitch is definitely temporary. The main reason I use it at all is that it has a landing leg. It was also free and fit w/o modification.
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post #8 of Old 03-29-2012, 09:59 PM Thread Starter
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Body:
I saw a method of construction over on Ih8mud I liked so I copied it. Essentially it is 16ga sheet w/16 ga 1" square tube for support.
I had the sides bent at a local steel supply, then built the trailer to fit them.
I sketched out what I wanted (several times), made a final draft on graph paper, then did a 1:1 scale drawing of the side and rear profiles on cardboard which I then used as a template/ plan for the build. More quality time with the hf bandsaw some steel and a welder got me to here.


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post #9 of Old 03-29-2012, 10:04 PM Thread Starter
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More body:



Pic w/TJ for size reference
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post #10 of Old 03-30-2012, 11:27 AM Thread Starter
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I welded all of the panels around their entire perimeter and then ground the seams smooth. Next I framed and skinned the lid and tailgate.
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post #11 of Old 03-30-2012, 01:15 PM Thread Starter
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Next was a rack for the roof top tent and mock up of tent install .




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post #12 of Old 03-30-2012, 01:48 PM Thread Starter
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The current project are the fenders and battery boxes. The fenders are built just like the rest 1" tubing frame skinned with sheet metal.


I ended up paying a local fab shop to bend the tubing for me as I could not get the look I wanted w/o a bender.
The fenders match the lines of rear TJ flares where they meet the body.
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post #13 of Old 03-30-2012, 03:04 PM
HAYSHAKER170
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Wow! Great job. I love seeing people take matters into their own hands.
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post #14 of Old 04-01-2012, 06:38 PM
Spuznick242
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Looks awesome! You just inspired me to suck it up and just spend the money already and buy my own welder!

DD- 1995 YJ 2.5L, Cat delete, 19lb injectors, 30/9.5r15
Trail Rig- 1994 YJ 4.0L, Rubicon Express 4.5inch lift, 1inch body, D30 Aussie, 33/12.5/r15 Cooper Mud Terrains, front bumper, rocker guards
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post #15 of Old 04-02-2012, 06:05 PM Thread Starter
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Thanks,
This is my first attempt at fabrication. I bought my welder and bandsaw to build this trailer.
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