Adventure trailer build thread. | Page 19 | Ford Explorer Forums - Serious Explorations

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Intro:
This is not a common build here on this forum, but this build is part of another long term build, that has been going on for 10 years now. I feel it is fitting to share this build here, since so much of it's companion is documented on EF. This thread is as detailed as my patience has allowed. I want to be able to help others that might be searching for methods/ideas, and "how to" for much of the build. I do belong to other Overland forums, and will link this thread from them, to share with others.

About:
This trailer is a short compact, stout, capable, high clearance, Swiss army knife of a camper. It is not a popup camper, nor is it a sleep in hard shell camper. It will offer all the creature comforts those do, but in a little different fashion. This style trailer, makes you enjoy the outdoors. You cook/dine, lounge & hot shower outside, but you sleep inside a roomy insulated roof top tent, 78" off the ground.

The tow rig:

The Black Hole

The entire build for the tow rig, has always been with this build in mind, and it has been extremely difficult to keep that to myself, and why it was built the way it was. It is a purpose build, with a specific objective.

The Objective:
To be the living quarters and storage, for off the beaten path journeys yet to come.
To have everything needed to sustain myself, and a few others, out in the middle of nowhere, only accessible by unpaved trails, such as old mining roads. Hauling all the boondocking gear behind, instead of overloading the vehicle's suspension. To minimize setup and tear down times for camping, and have camping items readily accessible, whenever needed.

The trailer needs to be capable of following wherever the tow rig goes. Matching tires, axle width, and the same, if not more height clearance as the tow rig. Sleeping & shelter for 4 comfortably, sustainable cold food storage, food prep space, gas powered cooking, AC/DC power supply, and hot showers for days at a time, are all the requirements for this build.

Goal:

This is the other half of that long term build plan. I am slow at the building and fabricating process, and this will take about a year to complete. Updates will happen as the build progresses. I have entered the 7th month of the build, and expect another 3-4 months left to get it road worthy at the least. Just like anything I have done, it never ends, and improvements will happen, as I gain experience & knowledge with what works best for me.

Baby steps:

This is the first time I have ever attempted anything like this. I am bound to make mistakes, and corrections/improvements are all but a guarantee. I do have a final vision for what I want this to be, as it has been a thought process for many many years now. Please bear with me as this thread goes. Some items won't make sense until it comes to be. I am not going to tell you how things should be done. I am just sharing how I did things on this build. Agree/disagree, like it or leave it, it's mostly a learning experience by mixing what I know, and what I had to learn, to get things as I want them. Definitely not for everybody. Heck, I know I will change things down the road, as I find ways to improve on it. That is part of the fun!



Why am I building this?
I'm Tired of ground tent camping all my life. Tired of the time it takes to set up & tear down. Tired of all the tedious packing, unpacking, moving things from place to place after every trip. Plus, I don't want a motor home that can't leave the roads.
I plan on getting lost a few times, venturing out to places unknown and unseen. We live in a large, beautifully gifted geographical location on the planet. Our own back yard is filled with amazing spectacles. Places that can only be seen on dirt trails, off the beaten paths, not by roads covered in pavement, and delivery trucks. Exploring into the dark hours of the night, and setting camp in the middle of nowhere, instead of heading back. We can traverse a lot of ground this way.

Kudos:

A few friends helped with this build, and I couldn't have got as far as it is without them. Special thanks to James, Matt, Kurt, Ryan, & Jacob. You guys rock!

A warning from the author:

This thread contains: Long drawn out boring tedious explanations, Dry humor, embarrassing anecdotes, speech in the 3rd person, countless pictures, and some content is for Mature audiences. There is a little for everybody here, but be warned, this is not your typical build thread, and not from your typical builder. I am not responsible for your emotional mood swings, due to reading this material. ;)

Edit: Progress pics as of 10/15/18. Getting closer every day!

Dr washed.jpg

RTT on front pass side full view.jpg


First real use!

Camp set 1.jpg

Camp set 2.jpg

Bat wing awning up.jpg



Current specs:
Main Frame- 12'.5"L x 48"W
Whopping 25" of ground clearance with 35" tires
Fenders- 72" Long x 14.00" Wide tapered to 0.00" in front
Cabin- 48"W x 72"L x 36"H
Overall Width - 76"
Overall Height - 68" Roof Rack lowered - 78" Roof Rack lifted
Overall Height- 80" With RTT stowed - 140" RTT open & rack lifted
Dry weight- 2300#'s

2"x3"x3/16" Steel Tube Frame, with 1 pc center tongue beam from front to rear.
3500 Lb Timbren Axleless Independent suspension
10" Electric brakes
35"x12.5" Goodyear MTR's w/kevlar & matching spare
15"x10" Mickey Thompson black satin aluminum wheels
Lock N Roll off road articulating Hitch
14 Ga steel cabin walls & roof
3/4" Ply floor, stained, sealed, & 5 topcoats of acrylic gloss clear
Commercial 60 Mil Waterproof TPO membrane under belly skin
12 Ga steel Fenders on Sq frame & 2" x 3/16" Round slider tubes
Spare tire mount on cabin front
16 Ga swing out 4'W x 2'D x 24"H Tapered Tongue box
16 Ga Side boxes with Tapered front compartments
Telescoping Roof rack (12") with scissor jack actuation
Two rear 31" BAL C leveling jacks & swivel plate base
Dual 5K swivel weld ring flat plate base Tongue jacks
ARK dual wheel offroad 750 HD Tongue jack
Slider system for hidden Solar panel storage
Dual 11 lb Propane tank storage mounts
Quick Disconnect Water supply
All Stainless & Aluminum hardware, where applicable

Interior:
Front compartment 48"Wx24"Lx36"H
Two side doors, and upper 12 ga shelf with expanded metal rear wall
Rear Compartment 48"Wx48"Lx36"H
3/4" PT wood flooring, custom finish, clear satin marine topcoats.
Tie downs on frame tubes
1-60W Led rear cabin, 3-10w Led front cabin
Wiring plumbed with flex and hard conduit
Split cabin with full rear cabin deck, tie down racks

Power:
Dual Group 31 MAGM deep cycle 110 AH batteries
110 shore
100W Renogy Solar
Charge:
NOCO Marine 110v 20 amp onboard Dual smart charger
30 amp Renogy MPPT Solar charger
140 amp traveling vehicle charge, via smart charger
Soon to come: 40 amp-500 watt DC-DC charger from alternator
Portable Valence 80Ah Lifepo4 Solar Gen w/inverter

Accessories:
4 season 23Zero 73" Walkabout RTT W/ large Annex room - telescopic ladder w/rung pads- Ext shoe bags-Led lights- 3" thick x Ca King mattress w/anti condensation mat.
Oversized high density 3" thick 56" x 96" mattress. Cold weather cover, additional secondary rain fly.
Rhino Rack 8.5' Bat Wing 270* Wrap around Awning (2019 version)
5Liter - 1.5 gpm - On demand instant hot water heater
ARB/ViAir 150 psi onboard air system
Ready Welder II
Slide out Kitchen/storage- 1/2" Baltic Birch, sealed/stained/clear coats 350# slides
ICECO VL45 portable fridge/freezer - AC/DC
Custom powder coated locking Fridge slide out.
Wireless controlled winch (upper roof rack storage, rear bumper hitch receiver)
Rear door interior fold down table
Dual 11 lb propane tanks (rear fender mounted)
Marine control panel, rocker switches w/circuit breakers, 12v battery meter, Aux outlets
30 gallon fresh water tank & 3.0 gpm instant on pump w/ inline filter
Trailer Harness Connection lock box
First Aid field kit (large)
Dual Fire Extinguisher's

LED Lighting:
Front- 2-45w dual pods w/amber fogs
Sides- 4-18w pods
Rock- 4-10w blue IP 67
Cabin- 1-60w 3 setting round rear compartment ceiling fixture, 3-10w pods front compartment
Tails/brakes/turns- 30w 6" oval
Reverse- 30w 6" oval
Markers- 3w red & amber
7 pin RV trailer harness & J box

Tongue box build:
Full box tube frame & 16 ga sheet, w/plate and tube gussets
Dual battery mount tray
Red oak Shelf for Noco dual 20 amp charger, 20amp solar charger, 12v systems (3) circuit breakers, fuse panel, main power cutoff switch
3 space divider walls & front storage shelf
Gas lift struts, 2"x 3/16" thick Aluminum lid hinge
Dual SS locking paddle latch handles
Dual 4" SS louvered vents w/bug screens
Pass thru power cord outlet with weatherproof door hatch
NOCO 110v wall power plug w/ weatherproof cover
2k locking latch to frame, & dual 7/16" clevis pins to frame
5/8" spindle for swivel action, for spare tire removal/security

Paint:
Frame- Chassis saver gloss black
Cabin Exterior- Acid etch primer & Single stage Gloss Black automotive 2k urethane
Cabin Interior- SW DTM Gloss White
Side & T boxes, All doors- Urethane Epoxy primer & Single stage Gloss Black 2k Urethane
Roof rack- Chassis saver gloss black
Fenders-Acid etch primer underneath & Urethane base topside, Black Raptor liner w/grip additive

Trim: Aluminum



Lots to add to that list up there, and I will as the build progresses. :)

I hope you enjoy the thread, as much as I have enjoyed the build itself.
 



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I am waiting to see what happens with the seller and Amazon first. If they do for some reason decide to sell it to me for the price they offered it originally, I will still want that warranty. If it doesn't happen, then I will attempt to get the refund.

Part I'm not sure about is, there is also no return option to click, on the warranty order.
 



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Had to go through Amazon to get a refund on a set of Mercedes fog lights. Its a process, but amazon will make it right
 






I have returned items a couple times over the years to Amazon w/o issue, but never had a seller just decide to return my funds and not sell me something after the purchase. Pitfalls of shopping online I guess.

Seeing what Amazon does with this situation is going to be interesting for me. Will they force the seller to honer the sale, and overturn the choice they made, or will they just lay down, and let it happen?

Onto the Chooch:

Tank & pump brackets made, and painted this morning. Should have all the holes in the trailer drilled out this afternoon, and tank/pump mounted.

Wiring & plumbing the tubes over the weekend, but the fittings for the supply line connections won't be, until I figure that out. Going with the reinforced tubing, as the Pex lines are too much of a hassle/costly.

Got a new 3.5" metal hole bit for the gravity fill spout. That one is going to be nerve racking, as the 2.5" hole I made for the box vents was crazy enough. Placement for this item is also a pita, as it has to be higher than the opening for it on the tank, which is 17" high. Front wall next to the spare tire is the only open wall space available for this. Fill tube will have to run under the front compartment shelf, and to the tank.
 






Today's Headlines read: Typical Chicago politics makes national news....80% of the media is against our country...Climate change is still happening since the birth of this planet.....Face Book has double standards.....But the biggest news of the day for me is, the Amazon conspiracy!

Checked the camp stove order status again on Amazon. They gave a tracking number. (?) Checked it, and it says it left the supplier, made it to the carrier, and is out for delivery. (??) Here is the weird(er) part.... It's not supposed to arrive for 2 weeks to a month from today. (????????)

No reply from the seller yet, and nothing from Amazon. I either got this for free, (and I will feel bad, as it's not what I want) or they are playing games with Amazon, and I will never get it. lol
 






Pump installed to the pass side wall close to the tank fittings. I had some treated self threading screws that worked perfectly for this, with pre-drilled holes.

Tank was installed with 3 angle iron brackets. Two on the sides, bolted thru the floor, with large fender washers underneath. One bracket on top holding it down, and also as a bracket to support the front edge of the storage top. Single E-Track black powder coated mounts used for the E-Track strap to hold the tank to the framing. The tank sits on commercial 60mm felt backed TPO. I need a couple more corner protectors for the strap. Stainless hardware was used for all.

Finally some progress pictures to share.

12v 3.0 gpm 7.5 amp pump. Self priming, and can run dry w/o damage. Instant on and shuts off with 55 psi. Runs silent (we shall see) and has rubber mounts for anti vibration. Screen filter between tank and pump, using 1/2" ID tube.

3.0 pump 1.jpg



This thing isn't going anywhere, no matter how bumpy the road is.


tank install rear.jpg

tank install rear dr side.jpg

tank install rear pass side.jpg

tank and pump view from rear.jpg


All this will be hidden by the storage build. The water supply lines will run along the side wall a few inches off the floor, to the rear. I have a couple options for how and where the fitting will end up for use with a coil line and spray head. Front will most likely run to the front wall for the external mounted water heater. The tank ate up 12" (depth) of floor space, 18" of height, and 35" of width. About 1/3 of the entire rear cabin below 18". It is right at the front of the axle, which helps a bunch with the 250 lbs filled weight.

More time will be spent figuring the wiring & plumbing routing, proper fittings than doing it I'm sure. More than a couple trips back & forth to the stores, is in my near future. Lol
 






Gathered some Bits for the water works. Unfortunately, Mother Nature is not being nice here. Basement and garage are taking on water, and all my attention for the day.

5 stores later, and a Ben Franklin worth of stuffs.

Water supply hardware.jpg


Hopefully tomorrow I'm not bailing and mopping, and can get back to this. Ahh....Spring......... you suck.
 






Hmmmm, it was 78 degrees with a light breeze and not a cloud in the sky out here.
 






Hmmmm, it was 78 degrees with a light breeze and not a cloud in the sky out here.

It got close to 70/sunny a couple days ago, then it decided to rain again, and not stop until sometime overnight. But we are earthquake, mudslide, & wildfire free still. lol
 






That's good, no catastrophic events please. We had temps just up into the 70's, but not we have that cold front and highs in the 40's to near 50's for a couple of days. I'm off today and tomorrow, working inside. My neighborhood is just getting fiber optic internet, I'm cleaning up my office to let somebody come in. I'm going to cut Comcast completely, $200+ a month is crazy.

BTW, did you know that you can keep your email addresses if you change providers?
 






Communications Companies have made us all evolve, into being internet dependent. They played the long game, and it is paying off for them, by us junkies hooked on what they are pushing. They now have control over us all, and can hold our lives for ransom, paid in increments monthly, at the price they set.

When my internet goes down, life pauses, followed by the sweats, shakes, and a loss of civilized language. 10 years ago, I could have cared less if I didn't have internet 24/7, or if it was slow. Progress right?

So I didn't get much done with the water system. Life got in the way, and the time spent on it, was more head scratching, than doing. I got to a point where I need to make another trip to the hardware store, and called it quits. Routing all the lines in a manner that works well, is hidden, and easy to get at to repair/replace items takes some serious planning. That and I hate plumbing, so it's a lengthy process for me. lol
 






Spent the evening inside the trailer. Had to gut the interior to run the pump wires, but it's all done.

Placed the switch in a convenient spot by the side door. Made a simple bracket to mount it. Had a pc of scrap of 1.5"w x 1/8", drilled a 1/2" hole, added a SS washer, and installed the switch. It's bolted to the pump brackets. It's plenty strong and secure. Couldn't be happier with it there. Added a SAE plug to the pump and switch, so the pump can be removed easily if needed.

pump switch.jpg



Tied it into the circuit for the Fridge, added a weather proof fuse holder. This circuit is a dedicated 8 ga 100 amp into the cabin, but the fuse is a 15 amp, running on 10 ga. I didn't want to bolt the fuse to the frame tube, as it might have got in the way of the fridge slide. I tucked it in onto the wall, using Gorilla brand 2 sided mounting tape. This stuff is crazy strong, and is supposed to hold up to high/cold temps. For the price, it better!

pump fuse.jpg


With the wiring done, I could get back to the plumbing. Well, with what I had at least. Still waiting on a few items to arrive. More on that later, easier to show y'all once done.

After running two lines for front & rear, I had close to 20 hose clamps, with elbows, and a Tee. Then there was the issue of two 1/2" tubes, and one 1.5" tube all fighting for the same space ran to the front wall. I said F this, and took it all apart. Decided to keep it simple, with less connections to leak, and only going to have one supply line for both the kitchen, and shower. It will be ran to the pass side wall in the back, next to the propane tank. I just have to change up how I am going to use and place the water heater. No biggie, as I already thought it out, and have a plan.

Should have the materials by this weekend, and able to finish up the plumbing. For now, this is where it sits. A manual throw valve between the pump & water filter. This filter will last a good long season, and it is installed with changing it in mind. I sourced some special fittings that go from 3/4" F/M-NPT to 1/2" barbed. They have nice thick rubber seals.


pump plumbed.jpg


There is ample room to reach the valve with the water tank in place. The filter is held nice & tight using a large quick fist clamp. All the clamps are wide Stainless. The drinking water filter actually surprised me with how many different things it filters. I have two more of them. One for a spare to change out, and another to hook up to a garden hose when filling the tank. Water will be filtered twice, so should taste fairly well, and no odors in case filling on the road at some service station, park well pump, etc... It doesn't filter petroleum tho.

water filter specs.jpg


That's it for a few days folks.

Wave your hand if you can still sit Indian style comfortably for more than a few mins. Discovered tonight, I can no longer do it. Damn old joints!
 






I use two of those same filters in line when filling the RV tank. I have been using them for years. You can get them in the RV section at WalMart,.
 






I use two of those same filters in line when filling the RV tank. I have been using them for years. You can get them in the RV section at WalMart,.

Good to know Wally World has them. That will come in handy, thanks!

So they must work well if you keep using them. Awesome.
 


















I just looked at my local store. They sell that 2 pack for $25. I should grab one for future use, before pricing goes up.

I go to WalMart for most of the RV consumables. They are by far the best deal out there.
 






Even the salesman at the RV dealership where we got our trailer said, as he showed us what we'd need, that we could get it cheaper at walmart. LoL TP, black tank deoderant, filters, hoses, all from walmart.
 






Ordered a few things online from etrailer.com, and decided to place them on will call, over the $12 shipping and 5 day wait. Just picked them up, so I will be ready when the last part arrives any day now.

This is one of them items unrelated to the water build. I talked about this a few posts back, and waited to order it until I needed other items. I can work on this now, and cross one more thing off the build list.

Xtreme weather silicone jacket trailer harness, with HD wires. This thing is beef, compared to the current harness. :)

Cold weather trailer harness.jpg
 






Part I have been waiting on arrived early. :)

Warning.... long boring technical post is in your future, if you choose to continue reading....... ;)


For the exterior water supply connection, I was at a cross roads with the install. The D&W supply box is what I wanted all along, but it turned out to be way bigger than I had liked. It sits flush on the exterior wall, but extends inward 8", and is a 4"x4" box on the backside of the wall. It also requires drilling a 3.5" hole in the side wall. I didn't like any of that. It would have interfered with the rear storage drawer box, and cutting that massive hole, just gave me the shivers.

Looking at that product online, I discovered they sell parts to it. Once I figured I could just by the main quick disco fitting, It was on from there! I searched some more, and found everything I needed for my idea on this. The rear interior section will now only extend 2", but the exterior side will extend 2.5". No biggie for the location will be, and is going to work out just fine for this trailer's application.

So if anybody want's to add an exterior water supply quick disco, that seals tight (check ball valve) when not in use, on a project, then this post is for you.

These parts are 1/3 the cost of the big supply box, and less intrusive to the body, but the downfall is it will extend 2.5", and not sit flush like the box does.

From left to right...
Spray away hose adapter- 3/4" MPT (Garden hose thread) etrailer.com
Spray away quick connect fitting- 1/2" FPT - etrailer.com
1/2"x1/2" MPT & 3/4" (#14) O-ring washers - Hardware store
3/4" MPT x 1/2" FPT Bulkhead W/O-ring washer (Used for making a drain on a rain barrel) Amazon.com
1/2" MPT x 1/2" Barbed elbow ( for this builds purpose, can use straight too) - Hardware store

Quick disco exploded view.jpg


Mocked up pre-install (connected water hose fitting on far left for visual)

Quick disco setup.jpg


I couldn't source a brass elbow at the store, only the plastic elbow. I will change it out when I come across one.

The discos from etailer, in packaging

Water supply quick disco.jpg


Bulkhead installed and supply hose connected

Bulkhead water supply interior.jpg


Exterior views of the disco installed and out of the way, but easy to reach for both kitchen & shower use

Disco front angle view.jpg

disco frontal.jpg

Disco rear view.jpg
 



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With the electrical completed, I was able to install the tank, and supply lines.

30 gal tank and pump install complete.jpg


Closer shot of one of the flooring brackets

30 gal tank dr bracket floor mount.jpg


Ok, here is some work not everybody is going to agree with or like, but it is what I felt at the time works for me. lol

I didn't want to cut the big hole for the rear exterior water supply, and this part demands an even bigger hole. I felt strongly against cutting a massive (feels like it) hole into the main cabins body panel for this, so.........

I weighted some pro's vs con's, and for me installing the water fill port inside was a better option. The tanks fill port was near the front cabins shelf. I already had it removed for the pump wiring, so it was simple to clamp it to a table, and cut the 3.5" hole for the fill port.

30 gal tank fill port.jpg


I will simply use a towel when I fill it from a hose with a shut off valve on the end. Easier to replace the shelf, then the cabin wall if I screwed it up.

So I thought it out before I installed it. In the event of a flop/roll on a trail (thanks to the flop picture @traveler), the tanks 1/2" vent tube would empty the tank on the interior. Can't have that happen now could we. So I added a manual throw shut off valve inline to the vent tube. So when traveling, the valves are closed, and have to be open when filling the tank, or while the pump is in use. I just have to remember to add it to the list of things to do for travel.

Here you can see the fill/vent tube leading to the tank

tank fill tube to tank.jpg


At least with the fill on the interior, nobody can mess with my water supply while parked. Never know what/where/when the whack jobs will be around. With this system completed, it's on to the next sourcing & gathering materials for the storage and kitchen build. Could take some time for this on to come to be. Some of these items are out of the current allowed funds! lol
 






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