post #1 of Old 12-24-2008, 01:10 PM Thread Starter
mcneil
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Trailer Build - an imitation M416

Here's another trailer build thread. I like the M416 trailers, but figured I could build it lighter if I started from scratch.

The idea was "multi-purpose". I wanted something I could drag over trails with camping gear one weekend, then swap the box for a flat bed and load up at home depot the next. It's the same length as a M416 with a little less rear overhang, and the track is the same as the TJ. I used the Moab wheels, so I could carry one less spare. But if I use my old stock 27" tires on steel rims, I can put a 48" wide flat deck on it.

This frame as it sits is made of 14 ga 2x4 square tube, with some .120 plate reinforcement in places. I used torsion half axles to get some extra ground clearance and shave off a few more pounds. The tongue has holes for either a ball or pintle hitch.

The cargo box isn't done yet, but is going to be fiberglass reinforced 3/4" plywood (gotta give my woodworking tools a chance too..)

Current weight: 180 lbs
GVW: 935 lbs (rating on torsion axles)

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post #2 of Old 12-24-2008, 01:24 PM
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post #3 of Old 12-26-2008, 11:58 PM
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Totally Cool !!! Great Idea and Good Luck, Hope it turns out like you want !!

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post #4 of Old 12-27-2008, 12:03 AM
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post #5 of Old 12-27-2008, 02:26 PM
LT1CJ7
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Cool looking trailer and nice work,
Although the 4 mounting bolts on the torsion axles look a little small.
I would at least use 1/2" grade 8 bolts.
I would also add 2 more bolts in the center (1 front side, 1 back side)
Some lock washers with Loc-tite or some poly nuts would be ideal as well.
Especially if you plan on draging that through the trails loaded.
It would be a real bummer to snag a wheel on a large rock and loose a wheel due to small weak bolts.

Last edited by LT1CJ7; 12-27-2008 at 02:30 PM. Reason: .
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post #6 of Old 12-28-2008, 09:31 PM Thread Starter
mcneil
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Quote:
Originally Posted by LT1CJ7 View Post
Cool looking trailer and nice work,
Although the 4 mounting bolts on the torsion axles look a little small.
I would at least use 1/2" grade 8 bolts.
I would also add 2 more bolts in the center (1 front side, 1 back side)
Some lock washers with Loc-tite or some poly nuts would be ideal as well.
Especially if you plan on draging that through the trails loaded.
It would be a real bummer to snag a wheel on a large rock and loose a wheel due to small weak bolts.
You caught those - I still have to tear it all apart for the final coat of paint, so I don't have all the hardware in. But the torsion arms came drilled for six 5/16" bolts, and there's not enough meat to go to 1/2". Yeah, loctite, gr8, & washers before it hits the trails.

More pictures.. I think it would have been easier to do the box out of steel. Doing finger joints on large pieces of plywood is just

Still need to add the tailgate, lip, and fiberglass over the plywood.

Someone PM'd me with a request for dimensions & measurements - I'll post drawings later.
Frame width: 38"
Frame tube: 2 x 4 x .083"
Axle to hitch: 76"

My new favorite tool is that riv-nut installer. I used riv-nuts to mount the body to the frame, and it was much easier than any through-bolt or weld nut method. Just drill a hole and pop the nut in.

Check out my "portable drill". I envy you guys with the mag mount drills.
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post #7 of Old 12-29-2008, 09:32 PM
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Is the nut rivet stuff you used made by Cardinal Components? If so do you mind me asking what it cost you and where you got it.

By the way, the trailer is looking great and I like the "portable" drill.

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post #8 of Old 12-30-2008, 11:48 AM Thread Starter
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Quote:
Originally Posted by surfthedrum13 View Post
Is the nut rivet stuff you used made by Cardinal Components? If so do you mind me asking what it cost you and where you got it.

By the way, the trailer is looking great and I like the "portable" drill.
The riv-nuts were Marson brand, from Grainger. I think the nuts themselves were about $14 for a 25pk, but the tool was $130.

The ultimate cordless drill:
Benchtop drill press hooked up to a inverter driven by 3 car batteries in a backpack.
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post #9 of Old 01-06-2009, 01:20 PM Thread Starter
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I need to post more pictures of the finished and loaded trailer, but I finished it up last week.

Test results are in. Just got back from a 3 day camping trip that went across the Mohave Road from Manix to Baker, then up to Death Valley through to the Owlshead Mountains, then over Mengel Pass to Trona.

The result? A broken torsion axle on the trailer on the washboard road leading to Mengel Pass on day 3. A crack started at a weld and ran through. I welded up a repair but more cracks started about 13 miles later. Finally it broke right next to the rubber mount, where I couldn't weld.

Grrr.. at least it's the part I decided to buy, not something I built. Rated to 935lbs? yeah right, there was no more than 200lbs on the rear trailer wheels.

Now I need to rent a truck to go up to DV to collect the trailer. I made it back to a road, so my plan is to just haul it home in the bed of a pickup.
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post #10 of Old 01-06-2009, 09:39 PM
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post #11 of Old 01-11-2009, 05:42 PM
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sweet trailer. keep us updated on how you address your problems.

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post #12 of Old 01-13-2009, 10:01 AM Thread Starter
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I did my third Death Valley run this weekend, this time with a rental van. The trailer was right where I had left it (thank you, NPS Rangers!), the only thing missing was the beer in the cooler and the empty jerry can.

As promised - frame drawings, and some more construction photos.

Note the broken tube on the torsion half axle assembly. (photo taken on the Mengel Pass trail out of DV)
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post #13 of Old 01-13-2009, 10:26 AM Thread Starter
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More random photos..

The company claims this was not a defect - that the torsion arm is vulnerable to side loads and I must have hit something. I'm skeptical, since the crack seems to have started at a weld defect.
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post #14 of Old 01-13-2009, 10:50 AM
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Those things aren't solid? It looks like it's made of rect tubing in that last pic. I always figures those were solid steel. I sure would not replace it. I'd go leaf spring and keep it dependable and simple.

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post #15 of Old 01-13-2009, 11:03 AM
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Quote:
Originally Posted by mcneil View Post
More random photos..

The company claims this was not a defect - that the torsion arm is vulnerable to side loads and I must have hit something. I'm skeptical, since the crack seems to have started at a weld defect.
wow, that didn't take long. Did you have it loaded down with anything insanely heavy? I believe I'd be talking to someone different wherever you bought those torsion hubs.

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