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View Full Version : Finally starting my teardrop offroad trailer build.


old_man
April 2nd, 2012, 13:04
I have been planning on building an offroad capable trailer for nearly three years and started picking up parts about that time. With being either flat broke or medically laid up, it kept being pushed to the background. I slowly purchased items when I found a killer deal so now I am starting the build.

For those who are not familiar with the term teardrop, it comes from the shape. They were popular in the 30's to the 50's and are starting to make a comeback. It is just big enough for two to sleep inside, while the back opens up and gives you access to the galley. Most are build on cheap harbor freight frames and the like and the body is totally wood. Being the pain in the ass perfectionist engineer I am as many of you know, I had to do it different. I am building a fully welded frame sitting on airbags and 31's. The upper section will consist of 1" steel square tubing with a sheith of Filon.

I am just getting started on the frame and have it about 50% welded. I am using a different suspension type from most as you will see as things progress. I have attached a pix from Outback Teardrops to give you a rough idea of the shape of the body. Mine will be a bit different but theirs will give you an idea. Progress from this point will be limited by funds. I rebuild and port power steering boxes and I am using that to fund my trailer.
http://www.outbackteardrop.com/maiden/m03.jpg

I will have a different style set of doors. As it turns out, that is the most expensive part of the build for me. A set of doors will run me almost $600.

http://i.ebayimg.com/t/RV-Teardrop-Tear-Drop-Trailer-Door-NEW-26-x-36-/00/$(KGrHqYOKpsE4jL0cdG,BOKej3Vd6Q~~_12.JPG


I originally snagged a trailer axle with the 5x4.5 bolt pattern and a drop axle. As it turns out the drop axle, that I intended to rotate up, just didn't work out height wise and I ended up just scavenging the brakes. I have sandblasted the brakes and painted them, along with buyins a set of trailer spindles and a section of 2x2x.25" box. I ended up cutting some new mounting plates and milling the holes.

http://i603.photobucket.com/albums/tt112/old_man_XJ/PartsLayout-Copy.jpg

http://i603.photobucket.com/albums/tt112/old_man_XJ/TrailerBrake.jpg


http://i603.photobucket.com/albums/tt112/old_man_XJ/CuttingBrakePlates-Copy.jpg

http://i603.photobucket.com/albums/tt112/old_man_XJ/WeldingCorners.jpg

bigalpha
April 2nd, 2012, 15:20
Awesome. Good luck on your build.

What exactly is Filon?

old_man
April 2nd, 2012, 15:28
Awesome. Good luck on your build.

What exactly is Filon?It is the sheet fiberglass covered with gell coat that is used on the out sides of motor homes.

old_man
April 2nd, 2012, 20:31
If you guys were wondering about how I was going to set up the suspension with the air bags, well I am going to run what is called a single link with a panhard bar. It is similar to what is called a trailer hitch suspension, only I am using a RE Super Joint. That will be my project for Friday.

After that I need to make a bender to arch the 1" square tubing. With that small of tubing, it is actually pretty easy. Stay tuned for the details.

Haulin
April 2nd, 2012, 22:00
Google rv surplus, their are a bunch in the Elkhart, In area. I picked up a door for around $100.

old_man
April 3rd, 2012, 07:48
Google rv surplus, their are a bunch in the Elkhart, In area. I picked up a door for around $100.Thanks for the idea but I am set on the doors in the pix. Wish I could find the manufacturer.

OverlandZJ
April 3rd, 2012, 15:01
Thanks for the idea but I am set on the doors in the pix. Wish I could find the manufacturer.


Post that pic up at Expo, somebody might be able to help ya out. If you dont have an account i can do it for ya..

Been waiting for this thread for some time, i'll be following. I'm sure it'll be an awesome build Tom.

Ronbo
April 3rd, 2012, 16:36
Thanks for the idea but I am set on the doors in the pix. Wish I could find the manufacturer.

That window looks identical to the ones used on the 'Little Guy' teardrops: http://www.golittleguy.com/teardrops/index.php

The Rough Rider model: http://www.golittleguy.com/teardrops/models/rough-rider/

A little snooping around, and I think they are made by Statewide Aluminum, and look similar to some of their livestock windows: http://statewidealum.com/livestock-trailers-statewide-alum.htm

Maybe that can help..

old_man
April 3rd, 2012, 18:08
Thanks for the lead. I will call them tomorrow.

Fore Wheeler
April 6th, 2012, 19:17
:eyes:


I'm watching.

shortxjdoug
April 9th, 2012, 05:51
ill be watching this as well, she's decided she wants a teardrop to pull with her rig. You think round tube could be used for the structure? thats what would be easiest for me to bend and work with

old_man
April 9th, 2012, 06:11
Personally it think it would be a ton harder. I will show you how to bend the 1" square tube easily and cheaply. I have just a bit left before I post pix of the trailer platform with axle and hitch. I will start the top later. While there it is a bit time consuming building the trailer portion from scratch, it is a lot tougher than the HF based solution.

I will be beating the crap out of this so I don't want it to break.

old_man
April 14th, 2012, 18:03
Pretty much finished welding all the platform and suspension. I built it upside down, now I have to figure out how to flip it over. I want to clean the garage a bit before taking pix. It is surprising how dirty a shop can get when you are welding, cutting, and grinding for a couple of days.

I overbuilt the heck out of the frame since I will be dragging it to hell and back.

Goatman
April 15th, 2012, 07:09
I love tear drop trailers, and for a long time I wanted one to pull behind the XJ. Before I could find a decent one to buy, I ended up getting a camper.

Good luck on the build, Tom, should come out nice.

old_man
April 15th, 2012, 11:40
I need to post a bunch of pix but first I have to take them. I got it turned over, ready to put on the wheels, but life has been hectic. My 94 yr old mother in law had a heart attack so things have been in a turmoil.

etatum21
April 19th, 2012, 17:41
Would you mind enlightening the group on how you bend the square tube? I like working with square tube but haven't figured out how to bend it properly without an actual tubing bender.

Fore Wheeler
April 19th, 2012, 17:44
is this done yet?






:D

200SportXj
April 19th, 2012, 17:58
Would you mind enlightening the group on how you bend the square tube? I like working with square tube but haven't figured out how to bend it properly without an actual tubing bender.

tape end, fill with sand, tape that end. put in vice, heat with torch and use a pipe wrench or your hand to pull it. will bend and keep form. google it

old_man
April 19th, 2012, 18:23
Nope, not even close. I have a three day weekend and hope to bend some tubing starting tomorrow. Remember that the radius on the bends is quite large, so the deformation is not great.

I hope you guys like my suspension. I have a few welds left and then I will paint it with a "Top Secret Coating" before I do some pix.

http://www.topsecretcoatings.com/cstore/pc/viewcategoriesAutomotive.asp?idCategory=46

I am also going to try and finish my vibration isolating offroad articulating hitch tomorrow. I made the first one of these about 40 years ago on the farm for pulling a sled behind a bailer.

old_man
April 20th, 2012, 14:18
Here are some pix of the trailer frame as I pulled it out into the sunlight for the first time. I still have to mount some shocks and finish the fancy coupler but things are coming along.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0077.jpg


http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0083.jpg


http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0085.jpg
Nothing like a little overkill on the draglink.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0079.jpg

old_man
April 20th, 2012, 14:23
The trailer actually articulates a bit too easy. I still have the socks to mount but I think I may end up putting a very small sway bar on. Anybody know of a vehicle that uses a thin sway bar? I just want it to return to neutral after flexing.

Sponge Bob
April 20th, 2012, 15:58
maybe a rear stock swaybar from a XJ

stumpXJ
April 20th, 2012, 16:07
I dont think its gonna flex anyhow. It will simply pivot on the coupler. I had a similar suspension on my old trailer, which was/is great for washboards and potholes, but it just pivots on the coupler, as its only being dragged behind the vehicle, and the axle isnt powered to initiate any torsional stresses. Sure, YOU can make it flex, but when its being dragged behind a vehicle, its not going to flex like a crawler would. It just pivots.

For example, here is what will happen. Notice the axle is still parallel to the frame? Its pivoting on the hitch, yours will do the same, even with the single suspension pivot point in the middle...because of where the bags are mounted. It'll work great as a supsension design, do get me wrong, but it wont flex like you are thinking.

http://www.sierra4x4trailers.com/wp-content/gallery/trailer/13.jpg


Looks great so far BTW!

old_man
April 21st, 2012, 13:37
The axle is parallel to the frame since you are running leaf springs. They have a neutral position, whereas air bags don't.

I dont think its gonna flex anyhow. It will simply pivot on the coupler. I had a similar suspension on my old trailer, which was/is great for washboards and potholes, but it just pivots on the coupler, as its only being dragged behind the vehicle, and the axle isnt powered to initiate any torsional stresses. Sure, YOU can make it flex, but when its being dragged behind a vehicle, its not going to flex like a crawler would. It just pivots.

For example, here is what will happen. Notice the axle is still parallel to the frame? Its pivoting on the hitch, yours will do the same, even with the single suspension pivot point in the middle...because of where the bags are mounted. It'll work great as a supsension design, do get me wrong, but it wont flex like you are thinking.

http://www.sierra4x4trailers.com/wp-content/gallery/trailer/13.jpg


Looks great so far BTW!

srimes
April 21st, 2012, 13:41
The axle is parallel to the frame since you are running leaf springs. They have a neutral position, whereas air bags don't.


Are the airbags plumbed together? If not they should balance.

old_man
April 21st, 2012, 14:57
Are airbags plumbed together? If not they should balance.
the current configuration has the airbags plumbed together. I probably will put a balancing valve between them.

stumpXJ
April 22nd, 2012, 05:39
Its simple physics. I also had air bags, trailing arms, and a panhard bar, exactly like you do. It will act the same as a leaf sprung trailer in regards to it 'flexing'. It will pivot off of the coupler, plain and simple. The trailer has only one axle (as apposed to a vehicle, jeep etc), and one other attachment point, the coupler. It will pivot on the coupler. Think about it. Better yet, hook it to your Jeep, put air in the bags, and try to make it flex naturally over terrain like the above picture - take pictures, then post them.

Like I said, for everything else, this design will be light years ahead of regular old trailer springs when it comes to every other aspect of suspension. Its just not going to flex like you think.

Looking forward to the rest of the build.

~ Stump

DrMoab
April 22nd, 2012, 09:45
The trailer actually articulates a bit too easy. I still have the socks to mount but I think I may end up putting a very small sway bar on. Anybody know of a vehicle that uses a thin sway bar? I just want it to return to neutral after flexing.

Moby1 trailers use a currie style swaybar on their teardrops.
www.moby1trailers.com

souske
April 22nd, 2012, 09:53
if you were offcamber with it, couldn't the downhill bag send its air to the uphill bag causing the body to lean over further?

Simply isolating them would prevent this, no?

old_man
April 22nd, 2012, 10:35
if you were offcamber with it, couldn't the downhill bag send its air to the uphill bag causing the body to lean over further?

Simply isolating them would prevent this, no?You are on the same page as I am. Now I just need to find a nice valve that I can ideally bulkhead mount in a 1/2" compressing fitting. It is either that or simply two schrader valves instead of one (probably the way I will go)

srimes
April 22nd, 2012, 10:47
You are on the same page as I am. Now I just need to find a nice valve that I can ideally bulkhead mount in a 1/2" compressing fitting. It is either that or simply two schrader valves instead of one (probably the way I will go)

I'd do seperate schrader valves. Simple.

Some IFS guys will run airshocks in the front and tie them together, as it forces more articulation.

If your trailer had 0 bushing bind (and a cg above roll center) with linked airbags it wouldn't stay level. Even on level ground it would flop to one side or the other with a little nudge.

souske
April 22nd, 2012, 10:52
What about a little manifold so you could link or isolate the bags as neccesary?
3/8 ball valves would do it.

philagony94xj
April 23rd, 2012, 14:03
What size, thickness square tubing did you use for the frame and bracing?

old_man
April 23rd, 2012, 18:27
What size, thickness square tubing did you use for the frame and bracing?
The frame is 2x2 and the cross braces are 1x2.

tone
April 29th, 2012, 05:04
Cool beans, I can't wait to see it finished!

old_man
May 4th, 2012, 14:00
I finally got the time to start bending the upper framework. People ask how you bend square tubing. Well being an engineer I always seem to build my own tools. I took some shortcuts on building the bender. I was at my local home improvement store, Lowes, and ran across something that cut my time way down. It was a round table top blank. It was 2 feet across and had a beveled edge.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0013.jpg

The radiused edge causes a slight indentation on the inside of the bend to allow the square tubing to be formed without kinking. The table top was just a tad thicker than the 1 inch tubing. I cut a slot about 60% across the top so a piece of 1x2 thick wall tubing could be inserted for a handle. I used some 1/2" scrap glued and nailed to both sides to strengthen the disc and to provide guides on each side of the tubing. I used some misc bracket material I had to fab the retainer. This thing is really just a knock off of a conduit bender.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0014.jpg

I then starte bending the side pieces. The trick is to figure out the bend allowance and exactly where the center of the bend will end up. Trial and error is the rule. Once that is done, you can bend your tubing.

I will follow up later with the top frame welded in place. You might not believe it but the top will end up weighting less than most wood configurations.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0016.jpg

tone
May 4th, 2012, 23:33
Literally a home-made bender. sweet

old_man
May 6th, 2012, 12:48
Slowly but surely it is comming together.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0020.jpg




I still have quite a few pieces left on the upper frame but I ran out of steel and money until payday.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0021.jpg

I have the parts to do the articulated shock isolating offroad hitch, so I will start on that this afternoon.

souske
May 6th, 2012, 12:54
Looks good

stumpXJ
May 6th, 2012, 16:45
Looking good man!

philagony94xj
June 3rd, 2012, 09:25
Any updates on this thing?! Looking forward to seeing some sheetmetal on it!

old_man
June 6th, 2012, 12:22
I have finished mounting the shocks and revising the air bag lines, as well as the offroad articulating hitch and offset tongue. I am starting the pre-wiring before adding the sheathing. I hope to take some more pix this weekend as I start fleshing out the rest.

Oh, by the way, there will be no sheetmetal.

jakeWI
June 6th, 2012, 16:41
Looking good. Going with all wood?

Fore Wheeler
June 6th, 2012, 16:53
It is the sheet fiberglass covered with gell coat that is used on the out sides of motor homes.

Looking good. Going with all wood?

Page one Jake. :D

old_man
June 6th, 2012, 18:07
Almost no wood. It is steel framed. The outside is covered with 1/4" ply covered with Filon, a fiberglass sheet like on motorhomes.

GSequoia
June 6th, 2012, 18:22
Tom's too old for wood. :eyes:

old_man
June 10th, 2012, 14:28
Finally got some time to work on the trailer again. I added the shocks, built the flippable tongue, the offroad hitch, and wired the temporary lights so I can get it inspected, titled, and get some license plates.



http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0026.jpg

The tongue can be removed and flipped upside down so it can be pulled by a regular height vehicle.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0027.jpg

I finished the offroad hitch as well.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0029.jpg


I cut the OSB for the floor and have started on sealing the bottom. I first coated it with ZinZer, followed by a coat of enamel, followed by rubberized undercoating.


http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0035.jpg

I also fab'd the brackets and mounted the shocks.

http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0032.jpg

old_man
June 10th, 2012, 14:34
I took it out on the street for the first time and it pulls sweet. They were working on the road and there was about a 4 in drop. I went over it at about 45 and the trailer landed firm with no rebound or bounce. Now on to finishing the steel frame now that I have figured out where the counter top, drawers, sink, and stove top go.

Can't wait to get it finished.

Fore Wheeler
June 10th, 2012, 15:01
looks nice. can you show better pics of the 'flippable hitch'?


also, why not use marine plywood for the floor? just curious.

jakeWI
June 10th, 2012, 16:18
looking real good!

old_man
June 10th, 2012, 20:02
looks nice. can you show better pics of the 'flippable hitch'?


also, why not use marine plywood for the floor? just curious.
Colorado isn't exactly swamped with marine plywood.

old_man
June 10th, 2012, 20:03
http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0028.jpg

jimgrms
June 12th, 2012, 08:21
Wanna build me one while your at it , Really nice work Tom looks good

Fore Wheeler
June 12th, 2012, 09:20
Great idea for the flippable tongue

neversummer369
June 12th, 2012, 10:48
Looking good old man!! :yelclap:

old_man
June 12th, 2012, 11:50
Wanna build me one while your at it , Really nice work Tom looks good
I've had a ton of people asking if I am going to build a bunch more. I might once I finish this one. I am working through the design and how best to fab it with the least effort.

My design is a tad overbuilt, but I'm a pain in the ass profectionist engineer, what do you expect.

Fred
June 12th, 2012, 19:19
Pretty cool, Tom. Make me a hitch for when I lengthen the tongue on the 416. :)

How long is it between the axle and the horizontal rotation axis?

old_man
June 13th, 2012, 06:41
It is quite long. I probably will shorten the tongue by 8-12 inches at some point, but it really pulls nice on the highway. The overall length is 13 feet, the body is 8 feet.

Fred
June 13th, 2012, 19:54
um, Mr. Engineer, quite is not a number. :) I'd guess 9' from axle to hitch, judging for the photo and the specs given. The M416 is about 6'. Time to contemplate surgery.

old_man
June 14th, 2012, 06:08
I might be persuaded to fab you up a hitch like mine. I have the steel, but I am short on hockey pucks.

bails85
June 14th, 2012, 17:22
Is the off road hitch/ Knuckle you have something you made? If so got any more info on it. If not where did you get it?

souske
June 14th, 2012, 17:38
I might be persuaded to fab you up a hitch like mine. I have the steel, but I am short on hockey pucks.

Is the off road hitch/ Knuckle you have something you made? If so got any more info on it. If not where did you get it?

Reading comprehension, important stuff

bigalpha
June 21st, 2012, 20:56
http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0028.jpg

What's the purpose of that one bolt that's sticking out at the 3 o'clock position?

Lowrange2
June 22nd, 2012, 04:31
Lateral tension to prevent a rattle in the hitch receiver? Idk, it was a guess.

old_man
June 22nd, 2012, 08:51
Lateral tension to prevent a rattle in the hitch receiver? Idk, it was a guess.
Bingo.

If you have ever pulled trailers, they always seem to have slop in the receiver and you get bumps and bangs. That isn't the bolt that is going to stay there. I have a shorter one and a lock nut for it.

You can also pull that assy appart and flip it so the tongue hangs down instead of being in the up position. That allows me to pull it behind my other vehicles if I want.

It also lets me pull the tongue to save storage space.

I'm busy prepping the XJ for a wheeling day, otherwise I would have some more pix to show everybody.

DrMoab
June 23rd, 2012, 09:32
Don't forget theft deterrent.

philagony94xj
August 6th, 2012, 09:54
Any updates on this Awesome trailer?!

old_man
August 6th, 2012, 10:07
I ran into some medical issues and have delayed working on if. Hope to start up again this week. I need to sell some crap to help fund the last of the steel and filon.

Anybody need a Henry AR-7 that has never been fired. It comes with a cleaning kit, about 700 rounds, and a zipper bag.

GSequoia
August 6th, 2012, 10:09
**** man if it weren't for stupid transfer fees I'd be all over the AR7. Great little rifle to sit under the seat.

87manche
August 6th, 2012, 10:49
I ran into some medical issues and have delayed working on if. Hope to start up again this week. I need to sell some crap to help fund the last of the steel and filon.

Anybody need a Henry AR-7 that has never been fired. It comes with a cleaning kit, about 700 rounds, and a zipper bag.

what kind of price, and are you willing to ship to my ffl?

obviously I'm not interested in paying to ship .22 ammo.

philagony94xj
August 6th, 2012, 20:11
Oh okay, sorry to hear about the issues lately.

Well most things that take awhile to build end up being VERY nice. I think this will as well. Good luck in the build and take care.

bigalpha
September 18th, 2012, 15:42
How're things going, old_man?

old_man
September 18th, 2012, 18:25
I've just about finished the last of the steel work. I have the inside and outside plywood and most of the rest of the parts. I just have to be able to get past all the other BS that gets in the way. Sound familiar?

I hope to post up some pix either tomorrow or the next day. Skinning the trailer is the small part of the whole thing. Its all the stuff you won't see under it that takes the time.

I got the state inspection and license plates. $20 for a 5 minute walk around and $80+ for the plates. OUCH.

stumpXJ
September 19th, 2012, 03:30
Its all the stuff you won't see under it that takes the time.

Aint that the truth. Something most people dont realize.. Looking forward to the pics.

bigalpha
September 25th, 2012, 18:46
Sounds like you're making steady progress though. I can't wait to see the final result!

old_man
September 26th, 2012, 12:12
Hope to skin the insides this weekend and maybe even start on the outside. If I were to build another one (a distinct possibility) I would modify the dimensions by an inch or so. I could cut down the cost of materials by a significant amount and simplify the build. That is why we build prototypes.

bigalpha
September 26th, 2012, 12:35
Build to sell, or build to be awesome?

old_man
September 26th, 2012, 12:37
I've had several people wanting me to build one for them. I am thinking about it.

I have also had quite a few inquiries about selling the hitches.

Wait until you see the crank down jacks I designed for all four corners.

bigalpha
September 26th, 2012, 12:50
I'm excited :D

Boss Cherokee
September 26th, 2012, 18:11
For example, here is what will happen. Notice the axle is still parallel to the frame? Its pivoting on the hitch, yours will do the same, even with the single suspension pivot point in the middle...because of where the bags are mounted. It'll work great as a supsension design, do get me wrong, but it wont flex like you are thinking.

I pretty sure he's right because you have no solid mount on the hitch. In the early 60's there was a trailer you could mount with 2 attachment points to your vehicle. It had one wheel that had spring loaded suspension and pivoted also. The trailer would lean with the tow vehicle as needed. The only way you'll get articulation from the trailer is if has 2 axles one at the front that can steer and one at the back. The front will climb or droop and the rear will do the opposite depending on the terrain. The trailer has no need to articulate when it is doing so at the point of attachment!

Boss Cherokee
September 26th, 2012, 18:26
You are on the same page as I am. Now I just need to find a nice valve that I can ideally bulkhead mount in a 1/2" compressing fitting. It is either that or simply two schrader valves instead of one (probably the way I will go)

You could use big rig air bag valves made by Haldex, or Bendix. Unfortunetly that would cause you to need an on board air comp. and tank. Your ride and sway adjustment would be great and automatic. When one side drops, the weight would increase as the trailer center of gravity leans toward the dropped side. The down side bag would inflate and the upside bag would be dumping air due to the shifted weight, and vice versa, assiting in and antisway like fashion.

old_man
January 2nd, 2013, 21:46
I ended up using two remote mounted Schrader valves. I have a leak somewhere. One side goes down after a couple of weeks.

DrMoab
January 4th, 2013, 09:16
I ended up using two remote mounted Schrader valves. I have a leak somewhere. One side goes down after a couple of weeks.

This is why I'm staying away from airbags.

I love the idea but reliability scares me...especially when I'm 200 miles from anything.

old_man
January 5th, 2013, 15:21
The air bag problem seems to have been a simple leaky Schrader valve. A good metal cap fixed it.

Here are some pix of the progress. I have started to skin the frame. Surprisingly, the order that you put things together is fairly complex.

http://i603.photobucket.com/albums/tt112/old_man_XJ/TrailerFrontPly_zps7c24ed5e.jpg

I added some radius tubing to the frame to make the 1/4" ply from without dimples.

http://i603.photobucket.com/albums/tt112/old_man_XJ/TrailerFrontInside_zps74a2900a.jpg

The ply is screwed into the frame with counter sunk machine screws. Once the inside ply is added, I will pull the wires, then cut 1" styrofoam before adding the external ply. The outside will be Filon, while the floor and sides will be outdoor carpet. The inside roof will be FRP.

The airbags make the trailer unstable when you are inside. The problem becomes finding a jack setup that will go high enough, not hand down too much when retracted, and won't break the bank is a big problem. Being an engineer and fabricator, I took an old school design and upscaled it for my needs. The jacks will raise the trailer high enough to change a tire or allow it to sit on very uneven ground.

Hopefully I can post the rest of the pix. It seems that Photobucket's user interface got hijacked in the middle of my post.

old_man
January 7th, 2013, 20:32
http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0038-Copy_zpscc5738fe.jpg

old_man
January 7th, 2013, 20:39
http://i603.photobucket.com/albums/tt112/old_man_XJ/TrailerLiftFull_zps883b1a51.jpg


I fabbed four of these jacks. I will be welding them in place tomorrow. I just love welding upside down. I think I can get the tires off the ground if I have to.

old_man
December 7th, 2013, 06:57
Finally I am going to be back home for about 10 days over Christmas and hope to finish this beast off. I want to be ready to do a Colorado Expedition type run. Here is the body of a post in the Colorado Section

For a long time I have wanted to do a multi-day trip around Colorado. I'm not talking about the hardest trails but a mixture from mild to wild.

It would have to be around the same time as ColoradoFest due to the fact that some of the trails are only open that late in the season.

My thoughts were to start off from Denver, run Red Cone and Radical Hill and camp that evening maybe in Buena Vista. The next day might be to do Taylor Pass to Aspen, have lunch, then south over Pearl Pass to Crested Butte where we would spend the second night.

From there we would head over Scofield Pass and Lead King, staying the night in Marble or Crystal.

From there the options are open. We could even add a day at Holy Cross in between Radical Hill and Taylor Pass.

The point is to do some fun wheeling without trying to trash your rig, see some awesome country, take some pictures and enjoy some camping with friends.

Is there any interest in this? This could most likely be done with a stocker with some help with the exception of Holy Cross.

The whole key is to do a low key, low stress time with maybe even some time to wet a hook along the way.

Fore Wheeler
December 7th, 2013, 07:37
:yellclap:

old_man
December 31st, 2013, 19:56
It never fails, when you have everything all planned out, something throws a monkey wrench in the gears. I got 12 days home for Christmas...I royally screwed up my back. I finally got a couple of half days of work in with the help of some Percocet and wine coolers and now I am heading back to the frozen north for another 5 weeks. I am to the point where things will come together pretty fast from this point forward. I got the inside roof finished, added some steel tubing, and got the walls cut out and the door mocked in. Now I need to order my lighting and run my wiring before I can really start to button it up.
http://i603.photobucket.com/albums/tt112/old_man_XJ/DSC_0057_zps4eef09b6.jpg



http://i603.photobucket.com/albums/tt112/old_man_XJ/5f324cc7-5d09-4a31-99f8-8a7635c8fedc_zps4faf353e.jpg

Fred
December 31st, 2013, 20:04
Hey, progress is progress. HNY.

old_man
December 31st, 2013, 20:08
If I had another day I could have finished attaching the interior walls, adding the Styrofoam insulation, roughed in the cabinets, and carpeted the interior, but alas I will have to wait another 5 weeks. By then I should have gotten the lights all figured out, ordered, and delivered.

I wouldn't have gotten this much done if I hadn't enlisted my 10 year old grand daughter. She gets in and around in the inside a lot easier than I do.

Bronzewyrm
February 1st, 2014, 11:21
im really liking this build. I have done a couple teardrops, and the project "family sleeper" (http://www.naxja.org/forum/showthread.php?t=1064254) this looks real close to what I had in mind for the next one.

Questions: Did you weigh it before flooring and interior? if so what is it looking like?
Do you have a "maximum weight" of some sort in mind? a target weight all finished up and loaded?
How many people will this platform support when your done? just you? the wife too, how many kids? and for how many days?

Not trying to bust your balls, im a curious fellow when it comes to trailer builds. This looks like it is going to hold up for years to come, I like the front radius profile, and im digging the suspension "tec" in this thread.
I cant wait to see it going down the road, thanks for posting the progress, my cogs are a turning now.

Props man!
Bronze.

old_man
February 1st, 2014, 16:33
im really liking this build. I have done a couple teardrops, and the project "family sleeper" (http://www.naxja.org/forum/showthread.php?t=1064254) this looks real close to what I had in mind for the next one.

Questions: Did you weigh it before flooring and interior? if so what is it looking like?
Do you have a "maximum weight" of some sort in mind? a target weight all finished up and loaded?
How many people will this platform support when your done? just you? the wife too, how many kids? and for how many days?

Not trying to bust your balls, im a curious fellow when it comes to trailer builds. This looks like it is going to hold up for years to come, I like the front radius profile, and im digging the suspension "tec" in this thread.
I cant wait to see it going down the road, thanks for posting the progress, my cogs are a turning now.

Props man!
Bronze.

Surprisingly steel is not all that heavy. I figure it will be about 800-900 pounds when finished.

For the most part, it will be for me mostly, the wife sometimes, and the kids will use it behind their cars to take the grandkids for camping trips.

old_man
December 14th, 2014, 19:15
Well I finally got the project back on track. I have been working 12 hour days 6-7 days a week for several months. Not much time or energy left over.

I have finished insulating the shell and putting the plywood on the outside. I hope to have the filon (fiberglass) on by this weekend. I will see if I can follow up with some pix in the next couple of hours.

It never fails. It appears that I have torn my MCL in my left knee. I accidentally hyper extended it. It is tons of fun going up and down the ladder with a bum knee.

The updated goal is to have it pretty much done by New Years.

old_man
December 21st, 2014, 11:30
Here is a quick shot of the insulation. I am using 1" Styrofoam. Sorry for the dirty shop but when you only get a couple of minutes at a time..........
http://i603.photobucket.com/albums/tt112/old_man_XJ/0991a25f-a88c-4c56-a39f-4b06381fd4ef_zps3cd133ae.jpg

Here is a pix of the passenger's side with the plywood underlayment. This will be covered with Filon (fiberglass sheet like used on motorhomes).

http://i603.photobucket.com/albums/tt112/old_man_XJ/70f64b96-561c-4e04-88b5-fb0fb4d9efd6_zpsc3f22ed2.jpg
Here is a pix of the driver's side. When I get the coins, I will be putting a door on this side as well. I roughed in the opening so it will be an hour job, max.

http://i603.photobucket.com/albums/tt112/old_man_XJ/634ee8e1-3b1f-4a81-aef9-d96f3fc73076_zpsb3d90778.jpg

One of the hardest things was to get the plywood to conform to the radius. I soaked it for multiple days and put it under tension. I even ended up sanding the back side down to allow it to bend better.

http://i603.photobucket.com/albums/tt112/old_man_XJ/20141207_134823-Copy1_zps6221ffe5.jpg

These pix are a bit out of date. I hope to get the Filon on before Christmas. Then I need to fabricate the rear hatch. I already have the bent pieces done, I just want to get the rest of the trailer skinned before I do the final fitting on the hatch and weld everything up.

Anak
May 16th, 2015, 20:12
Any more progress?

I love what you have done so far.

old_man
May 17th, 2015, 11:17
Tons. I will see if I can take some pix today. I am doing the galley at the moment. I have sheeted it with filon on both sides and hope to finish the top today and put in the carpet.

Anak
May 21st, 2015, 07:11
I am looking forward to seeing them.

Fore Wheeler
May 21st, 2015, 07:13
I am looking forward to seeing them.


X2

GSequoia
May 21st, 2015, 09:58
You should also be posting in the Off-Road and Expedition Trailers (https://www.facebook.com/groups/offroadtrailers/) Facebook group.

Lowrange2
June 2nd, 2015, 11:21
I'd just like to point out that I'm subscribed to this forum. I'm also subscribed to this thread. In my UserCP this thread just sits there. In plain sight. I see it constantly. I see mention that new pictures were to be posted May17 or the next day. It's June 2nd and there has been no update. I'm not sure what to do. I need updated photographs as soon as possible, please. Thank you.

old_man
June 2nd, 2015, 11:24
Are you copying my design? I'm sorry if my performance doesn't meet up to your expectations but if that is so, tough.

I've been sick and had a daughter getting married. I will post up the pix when I get around to it. If that isn't good enough for you, then unsubscribe.

old_man
June 2nd, 2015, 19:43
Here is a front view. The diamond plate has not been attached yet. There is some L shaped diamond plate sitting on top that I will be adding to the bottom sides. As soon as I get that mounted and the last of the filon on the rear, I will put the standard aluminum channel on the front/top/back edges.

http://i603.photobucket.com/albums/tt112/old_man_XJ/Shieth%20Drivers%20Side_zpsu5mdclqw.jpg


Here is quick shot of the side with the door.

http://i603.photobucket.com/albums/tt112/old_man_XJ/Shieth%20Passenger%20Side_zpsoxavezzv.jpg


Here is a quick shot of the back galley area. I am building the under cabinet face frame for the two doors on the sides under the sink and stove top, and then the frame for the three pull out drawers. The white is just a sealer for the inside of the cabinets.

Just forward of the sink and stove, there will be a vertical face frame and cabinet doors.

If you look at the large flat counter top area, that will be partitioned across with the cabinet doors. The front edge of the flat area will have a face frame and cabinet doors opening into the interior. All cabinet doors will have the European style hidden hinges and fancy push button latches.

http://i603.photobucket.com/albums/tt112/old_man_XJ/Rear%20No%20Cabinets_zpspsobtuzf.jpg

GSequoia
June 2nd, 2015, 19:45
Are you copying my design?

Andy's too cheap to copy your design. I think he just wants to see pretty pictures.

Lowrange2
June 3rd, 2015, 09:21
Are you copying my design? I'm sorry if my performance doesn't meet up to your expectations but if that is so, tough.

I've been sick and had a daughter getting married. I will post up the pix when I get around to it. If that isn't good enough for you, then unsubscribe.

lol, Pretty sure you took that the wrong way. No. Not copying your design. Like Geoff said, I'm too cheap for that. That was a very sarcastic post. I've been anxious to see how your project is coming along.

Looking good.

old_man
June 3rd, 2015, 09:39
lol, Pretty sure you took that the wrong way. No. Not copying your design. Like Geoff said, I'm too cheap for that. That was a very sarcastic post. I've been anxious to see how your project is coming along.

Looking good.
I was hoping that was the case but you caught me sicker than a dog and my wife and daughter as well. We have been sick for almost 3 months. It started with the flu, then changed to a nasty sinus infection, then on to bronchitis. I am being pressured from all sides. Heck, have to help my daughter get into her new home and I am moving to a new home in three weeks as well, while working 10 hours a day.

Moving my garage/shop is a BIG undertaking. It would be nice to have the trailer done.

Never marry an interior decorator. I am finally getting her to downsize from 6800 ft on the golf course with an indoor pool and hot tub, to a 5800 ft on the lake (4 years ago) , down to a 3800 ft. with no golf course or lake. (now).

There is going to be one hell of a garage/moving sale.

Anak
June 4th, 2015, 19:34
Love the updated pics.

Thank you.

Good luck on the garage sale and move.

Lowrange2
June 5th, 2015, 10:51
I was hoping that was the case but you caught me sicker than a dog and my wife and daughter as well. We have been sick for almost 3 months. It started with the flu, then changed to a nasty sinus infection, then on to bronchitis. I am being pressured from all sides. Heck, have to help my daughter get into her new home and I am moving to a new home in three weeks as well, while working 10 hours a day.

Moving my garage/shop is a BIG undertaking. It would be nice to have the trailer done.

Never marry an interior decorator. I am finally getting her to downsize from 6800 ft on the golf course with an indoor pool and hot tub, to a 5800 ft on the lake (4 years ago) , down to a 3800 ft. with no golf course or lake. (now).

There is going to be one hell of a garage/moving sale.

They maybe 6,800 sqft houses?!

I've got a 2,200 sqft house (Me, wife and 3 daughters) and I feel like it's huge. lol

GSequoia
June 5th, 2015, 13:03
They maybe 6,800 sqft houses?!

I've got a 2,200 sqft house (Me, wife and 3 daughters) and I feel like it's huge. lol

Shit, mine is 720 :cry:

old_man
June 8th, 2015, 17:42
Got a little bit more done. I put the diamond plate on permanently, including the bottom rail. I also added the beauty trim that seals the joints up the front, across the top, and down the back.

http://i603.photobucket.com/albums/tt112/old_man_XJ/XJ%20Pix/diamondplate1_zpskde1gwgi.jpg

old_man
June 10th, 2015, 07:22
Hopefully things will progress faster now. I spent $200 going to the doctor and found out that the reason I have been sick for the last three months was the flu that triggered a sinus infection causing bronchitis that then caused pneumonia. Got some drugs and hopefully will start feeling alive again shortly. I was coughing so hard that I cracked a rib. :puke:

Johnnie Walker
June 29th, 2015, 23:46
I hope all is well for you and your family.
And, also looking forward to updates on this awesome project.

old_man
June 30th, 2015, 05:19
I need to take some more pix. The rear hatch is completed. I just need to finish the cabinets and lay some carpet. We are getting ready to move, so time is tight.

old_man
July 27th, 2015, 08:23
Moving day. Didn't completely finish it before I had to move to the new house. I had the air bags a bit too inflated and between the jeep and the front of the trailer, I had about 1500 pounds of tools and crap. Even at that, it pulled nice.

http://i603.photobucket.com/albums/tt112/old_man_XJ/20150725_124223_zpsr97y1myp.jpg

Anak
August 5th, 2015, 07:07
I love finding progress pics on this trailer.

Congrats on getting it roadworthy in time to help you move.

Boostwerks.com
August 7th, 2015, 10:05
How painful was the registration process here in Nor Co btw? I'm looking into building a camp trailer as well. :thumbup:

old_man
August 7th, 2015, 11:30
It wasn't that tough. You do have to fill out some simple paperwork and have the State Patrol inspect the trailer. Your plates will run around $75 a year.

GSequoia
September 17th, 2015, 09:19
Your plates will run around $75 a year.

Ouch! You got California beat on that. I pay about $30 or so ever five years for my "permanent" plates on my M416.

*yes, I also find their definition of permanent to be amusing.

old_man
August 22nd, 2016, 20:10
Finally getting back to working on this project. Between working 60 hours, being sick, and tearing up a knee, and the wife having two surgeries, and throw in moving, it has been a crappy year. Trying to finish up before having the knee operated on in the next month or so.

http://i603.photobucket.com/albums/tt112/old_man_XJ/20160820_211336_zpsk7hvlcch.jpg

http://i603.photobucket.com/albums/tt112/old_man_XJ/20160822_062848_zpsavgpij1i.jpg
I stick built the frames, doors, and even the drawers with full extension slides.
I still need to finish putting in the rest of the latches and handles, but it is coming along.


http://i603.photobucket.com/albums/tt112/old_man_XJ/20160822_062858_zpsopq6il4k.jpg


http://i603.photobucket.com/albums/tt112/old_man_XJ/20160822_062906_zpsjb0n6xlk.jpg

http://i603.photobucket.com/albums/tt112/old_man_XJ/20160822_062931_zpscqkbhwrz.jpg

old_man
September 12th, 2017, 20:22
Got some unexpected time off and finally got everything wrapped up and ready to go.
https://vgy.me/hRd1r1.jpg

Anak
September 13th, 2017, 07:12
Awesome.

I need to start my build. Mine will probably take five years or more too. And that would probably work out about right: Finish it up about the time I start kicking Varmints out of the house. Be just about the time I need to start convincing The Bride she needs to go on Jeep trips with me. I will need the teardrop then.

old_man
September 13th, 2017, 10:00
Between working 60+ hours a week, working in Minnesota for close to two years, three surgeries, a new home, and a daughter getting married, it surprised me it took so long.

Heavyopp
September 30th, 2017, 19:58
Read this whole thread tonight -- great trailer build -- Being fairly new to NAXJA I never saw this thread before today

Now that you have a trip on it, How did the suspension preform? Would you still build it the same way?

old_man
October 1st, 2017, 13:54
Pulls flawlessly on the highway and with the isolation hitch, you really couldn't hardly feel it on the trail. With the shocks and air bags, it rode great.