Adventure trailer build thread.

gmanpaint · October 8, 2018

Last week was a busy one for me between the ole 9-5er, and a weekend spent working on the tow pig with friends.

I did get the RTT ready for install, and we got it up on the rack, and bolted down. I need to adjust it a little, before final positioning. Not a big deal here, but....

We placed the RTT on in the driveway, then quickly did a squinted one eye neck snap, after looking at the height of this, and the door opening. The ladder had to come off. Tape measure, now said they matched in height. lol Ok, air down to 4 psi, and pushed it back in. Ladder won't go back on (bolted) until it's time to use it for an adventure.

Next up will be the awning mounts, and get that on. It has Led lights built into it, so it has to be wired as well. Already have the wire for it coming thru a cable gland for it, and to the panel switch.
Edit: Awning is installed, and wired up. Tent was centered over the screw jack, bolted tight, and cover installed. Looking pretty slick!

No pics yet, but it will be worth the wait.

I realized last night, that I only have 1/4" of room left between tire and fender center tube brace, after max up travel on the axles. I might remove the center tube brace to gain another 1" for mud/rocks/snow stuck to the tires. This isn't really a big deal, as there are other bracing and the 12 ga fenders are fully welded to the 1.75" outer tubes, and 1" tubes at the main frame. I have a lot of work left to do on these fenders as is, and this will just be a minor thing. Just glad I noticed now, not on a trail.

gmanpaint · October 11, 2018

These tent & awning pics are going to have to hold you & I until I get it out and opened up.

On without the cover, and showing the green 3.5" thick mattress. It's folded in half when stored.

RTT no cover pass side view of mattress.jpg

Front close up cover on

Rear close up

Pass rear corner

Dr side rear corner

Dr side

Full frontal (heh heh)

Gap between tent and awning for zipper access

Full view front dr side angle

Pass side full view (blurry, again...sorry!)

What the RTT looks like open (stolen pic from CVT site) Without the annex room on

With annex on. Ladder is inside this room, so you can come down and not be in the elements to change, and big enough not to step on any guests sleeping. It has a thick vinyl floor, a door on each side, and completely sealed up to the top. I purchased and installed an extra track, to keep the cover on, and not have to use the same track for both cover & annex. Speeds up setup/tear down times, and adds convenience. This is opened to the rear, where mine will open to the pass side, and awning opens on the drivers side, and wraps 270* around the rear of the trailer.

And the severe weather cover on

It has a rainfly as well, and both tent & fly, have clear vinyl/screens skylights, for an open sky view from inside. Led lighting inside it as well.

This is the awning. I opted for the red perimeter stripe for a visual effect instead of one solid color. It has LED lights built into the arms, and a switch wired in to the panel already. I made a harness for it last night, using the weather proof quick disconnects. Awning side harness stows away inside when zipped up. Its 13 foot long on the side, and 13 foot across the rear. Self supporting, but does come with high wind tie down straps. I made strap points to the corner led pod light brackets just for these, and have special re-bar type stakes for them too.

One of two 11 lb pancake propane tank & mount. Still have to modify to shorten wall side to bring it in another 2". Will be one on each side.

LED Pod with smoked lens. 4 total, on each corner

LED pod with smoked cover rear dr side.jpg

That's it for today kiddo's!

gmanpaint · October 14, 2018

Started on the fenders yesterday. It's time to get them prepped for the Raptor liner.

Stripped the temporary chassis paint off the Passenger underside, and removed the center (front to back) support tube. Gained another 1.5" tire clearance.
Masked it all off, and sprayed the self etching primer to the raw steel. That only took me 9 hours, on my back, on cold concrete.

My back, shoulders, and neck, feel like I was in a car accident this morning from doing that. Going to try to attempt the other side today. Pics later tonight,.... hopefully.

BKennedy · October 14, 2018

Get a couple of those $5 movers blankets on your next visit to Harbor Freight. Lay on those instead of concrete. Throw away when they get too ugly.

gmanpaint · October 14, 2018

BKennedy said:
Get a couple of those $5 movers blankets on your next visit to Harbor Freight. Lay on those instead of concrete. Throw away when they get too ugly.

That's a good idea. I actually have one of those. Thanks.

I haven't laid anything down, as I am making such a mess stripping this chassis paint off, I have been sweeping it all up as I go so I am not rolling around in it constantly. lol

Think I have over stretched my quads, sitting ass to ankles, shins to floor. Walking around with rubber legs today. The area above the wheels, are too high to lay down, and too low to kneel upright. I can't sit Indian style on my ass and work at the same time, or I will fall backwards. lmao! It's Hell getting old.

2.5 hrs of scraping so far, and 1/4 done. This side isn't coming off like the other. A lot of it will have to come off with the paint remover wheel and grinder. Time for the dust mask.

BKennedy · October 14, 2018

Sounds like its the same height as parts of my Explorer. Too high to reach lying on my back, too low to sit up underneath. Sometimes, I rest my head on a 6x6 block of wood to keep from getting a sore neck. Sounds weird, but it was there and it works.

gmanpaint · October 14, 2018

Another long day, to wrap up another weekend on this thing. Only carnage was a paint chip in my eye, and a good flush, with some Q-tip pokes to get it out. I wish the eye didn't have a memory for pain, because it still feels like it's in there, but it's not.

Not much to share here really, with this work, and kind of a boring update. Ahh well, for documentations sake......

Way way back before the trailer made it home from the frame build, it had the chassis paint put on the underside of the fenders, just to keep it rust free, knowing it had to be removed someday. Knowing it would be a long time, before it was ready for the liner, this was an easy solution, so we could move on to the next step back then. In hindsight, I wish we had just did the undersides, like the top, with the acid etch primer, and body paint. This was a pain to remove, but it worked. No rust was found this weekend.

The Raptor liner can't go over this chassis stuff, as it doesn't bond to the metal like a bonding primer does. It would flake off, if I went over it with the heavy liner, and the tires are going to be hammering it with debris. I actually don't like it all, but James (Body shop guy) said the stuff he uses will work just fine for it. One day, out of the blue, he sent me pictures of the frame on the rack, and painted with it. Guess he had a slow day, and was bored.

Any hoot....
After cutting off the center tube under the skins, and grinding the welds off, I began scraping it off with 1" putty knives, (flex and stiff). They got the majority of it, then out came the brushless grinder with sanding discs, wire wheels, and paint stripper wheel. Hand sand with 80g blocks, cleaned off with the air hose, then a final acetone bath. Funsville.

Masked off what needed for spraying the acid etch primer, and shot it all a couple of times. It's now ready for the topsides to be scuffed/cleaned/masked, for the Raptor Liner coating. Will try to find time during the week, if not, next weekend.

When the tires are on, you can't even see inside the fender wells. I didn't have to be as picky in here, and I did leave a couple of booger welds alone, as they won't be seen. It might haunt me in my sleep, knowing they are there tho. lol

I have a fresh tube of body seam filler to use here and there, before the liner goes on, to seal some things up tight.

Summer has officially left, and I think we might get 2 weeks of fall in, before it turns to winter here. 90's with AC on last week, and lows in the 30's with furnace on now. Fall is my favorite season, and I feel ripped off. bah...

CDW6212R · October 15, 2018

Keep it up with the weather changing while you can. We just bean to cool off, lows in the 50 range. here we'll get about two weeks of Fall, and then it will get warm again in late October of November, and then go full cold. We're just getting Fall weather now, the leaves are beginning to drop.

gmanpaint · October 15, 2018

Dang, nobody noticed the radius bends on the square tubes. Lol

Temps tend to bounce around here too, but the last couple of years, it just rained non stop, then froze until spring.

If I can find a decent cover for this thing, I can put it outside, when I need to heat the shop, to fabricate and paint.

Started masking for the liner work tonight. One side done, and put a fork in me. Mondays are a nightmare at work and I just want to shut my brain down for a rest.

Hello..... couch!!!

gmanpaint · October 22, 2018

Last 7 days have been insane at work. Haven't had any time really to work on this. Only managed to finish the masking, and get the sanding done for the Raptor liner. Man, that was a weird feeling sanding with 60 grit on new paint. This week has already shaped to be just like last week, so not much other than maybe getting two coats of liner on. Maybe....

Turdle · October 23, 2018

This is coming along real nice. Thanks for posting pictures of the progress.

I hope the busy at work means money and not cleanup.

gmanpaint · October 23, 2018

Turdle said:
This is coming along real nice. Thanks for posting pictures of the progress.

I hope the busy at work means money and not cleanup.

Thank you sir!

Busy managing ongoing jobs, dealing with problems and coming up with solutions, preparing for a convention this Thursday, reeling in new clients, estimating new jobs for a chance, working with nightmare Insurance adjusters, and dealing with all our labor crews. Fighting to keep an income going for this winter, and trying to make **** happen, ain't easy here.

I need a hat with more than 6 bills on it lately.

bats · October 23, 2018

That thing is sexy! I've been tossing around the idea of an adventure trailer like this since I switch vehicles so often.

BKennedy said:
Sounds like its the same height as parts of my Explorer. Too high to reach lying on my back, too low to sit up underneath. Sometimes, I rest my head on a 6x6 block of wood to keep from getting a sore neck. Sounds weird, but it was there and it works.

A partially deflated boat fender works well too.

gmanpaint · October 23, 2018

Bats, when you get one built, you can meet us at the Gateway Arch, and join in on crazy 2 week adventures out west in the Rocky's, Deserts, and Canyon lands! Gonna need a 302 in that B2 tho.

I need to make a height adjustable creeper. A strong pneumatic ram like used on an office chair to a plate, and to a 4 wheel dolly. Two rams going on an angled plane to get from 4" to 2 foot high. Lol

CDW6212R · October 23, 2018

When you/we win the big lottery, then you can pay someone else to do the hard work. Wishful thinking, nobody I know has won a lottery, it's always someone traveling through the state.

gmanpaint · October 23, 2018

Wouldn't that be nice? After family is set for life, I would throw bash on a cruise ship, and take everybody that has ever followed along, in my crazy build threads. I hear they rebuilt the Titanic, and the Maiden voyage is going to be the exact same route as the originals. I smell a new movie. Titanic, part duh?

I grabbed a ticket for the Mega & powerball today. Over $2B combined up for grabs. Crazy!!

CDW6212R · October 23, 2018

You couldn't pay me a $B to go on the next Titanic. I'd buy a radio station and cut out all of the commercials.

traveler · October 24, 2018

I think you're having a positive influence on Sandi. She has gone from "Why would you want a smaller camper?", to "we could sell the camper we have to help fund a tiny camper build" to "I think we should build a small camper (teardrop) together". Of course this most likely means I'll be building while she chooses colors, etc. (sorry to sound sexist, but...) But it will mean easier financing.

PS I went back to page one and the basic platform shown on the second post is exactly what I need for my build, with perhaps slightly different dimensions to accommodate the sleep in vs sleep on styles.

gmanpaint · October 24, 2018

Sweet! We knew she would come around if you kept on her! lol That would be a great couples project for sure. One thing I have learned, is women are far more detailed orientated then men will ever be. She would be a great asset in the build.

Suspension choice will matter how you build the frame tho. Regular axle/leafs or Independent suspension. Choose this first, and build around it. Other options for the frame:
1) Instead of having the center main tube go all the way back to the rear, stop it about 1/2 back from front of box (not tongue). This leaves a space for a water storage tanks tucked up under, after the beam.
2) Have the main front to back tongue beam, under the boxed frame, instead of thru like I did. This gives you a place to run all the electrical and plumbing along side it, and out of harms way. Mine all had to be routed on top of frame, and thru the front of the main box for routing. Routed under, you can bring wires up thru the flooring, where needed.
Just remember that the wheel wells have to be around 14-16" deep, and you want to keep the trailer no wider than the Explorer's width. Mine is a dead even match, with a 48" wide cabin and 12.5" wide tires, with a 2" gap between them and the frame rails, and the fender tubes push past them 2".

Once the frame is figured out for all that, it goes pretty quick, as you just building upwards now.

gmanpaint · October 24, 2018

Quit working mid afternoon today, so I could get the fenders finished. Temps was around 59* this afternoon, and the heaters warmed it up to 70* easily. Perfect temps, and had to take advantage of it.

U-Pol Raptor Liner was the product of choice for this. UV protection, no rubber tire chunks to gas out and fail, (like most other bed liners), 2 part / 3:1 catalyst Urethane system, that toughens & strengthens the surfaces. It comes in either roll on or spray on. The only difference is in the packaging and what comes with the kits. It's the same juice in both.

I was going to spray it on with my cup gun HVLP, but since I wanted to add the silica grip additive, I needed the 2.0mm tip, and couldn't find it anywhere.

I got the roll on kit, as it was cheaper than the spray kit that comes with more juice, and a shutz spray gun. I read up on some reviews, and people said the supplied texture rollers fell apart fast, if your doing anything but flat surfaces. Well, there is definitely more than flat on these fenders! I knew exactly what I needed. Picked up a textured roller made by Rustoleum for their Re-Store decking paint. Cut it into 3 small rollers with the hacksaw, wrapped a 4" roller frame ends with tape to make it snug, slipped one of them on, and Bam! Bob's your painter.

After mixing 1 of the 2 cans of juice for 2 minutes, I brushed everything I couldn't fit the mini Raptor rollers into. Used 1 roller (comes with 2) per fender on the 1st coat. That's as far as they got before falling apart. Good enough for me. Time for a break. This stuff needs a 60 minute flash over time @70* before you can apply the 2nd coat.

(Cue the music from Jeopardy) ..................................

Ding!

Mixed up the 2nd bottle of juice, and used the Re-store roller for the undersides of both fenders. This roller has an initial heavier texture to it. Trick to using it, is after you lay it all off, let it set for about 1 min, then lay it all off again nice and easy with straight strokes, from edge to edge, the same direction. Bam! It's a match.com. That **** will fly straighter than dive bombing falcon.

Ok, at this point, I added the black grip additive to the bottle, and shook it like a Poloroid picture. Tops and tubes got the 2nd grip coat, and laid it all off the same way, making sure not to leave any lines, or visual patterns. It would have been so much easier to spray this, but this actually worked pretty damn good.

Wasn't wearing my respirator, and it was time to get the hell out of the Nazi gas chamber. I was so high, I could have been duck hunting with a rake, and some fresh air was the cure. Let that be a lesson to you kids, always wear protection.......Uh.... yeah, just do as I say, not as I do, and your kids won't have 3 eyes, and 10 thumbs. K?

I had about 4 oz left in each 32 oz bottle. You only have 60 mins to work this stuff once mixed, then the rest is trasharoo. It cleans up with acetone or lacquer thinners. The kit came with 6, yes....6 pairs of thick black 10mm latex gloves, and one pair lasted thru the entire deal. The 2 thick roller trays was the best disposable trays I ever seen, and shaped for 5" rollers. I mean U-Pol gives you some quality stuff for your buck, and was pleasantly surprised for a foreign product.

Some after pics

Adventure trailer build thread.

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