Adventure trailer build thread. | Page 18 | 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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Lol an ensuite might come in handy
 






I guess. Lol.

Some primitive camping In areas of moab, you actually have to have something like that, or the rangers make you leave. They don't want you leaving your worthless crap behind I imagine.
 






It's 50% off if you wanna take advantage of that offer...
 












Hahaha better than a toilet seat in a Homer bucket:p

So.... Progress?
 






Well, it's not really a topic I was planning on getting into on this build, as it is a camping accessory.

I do have a small camping chemical flush tank commode, but haven't used it since the kids was little. These days a portable folding seat, with special bags and chemicals is used, then disposed of after camp break down. An exterior mounted Trash a Roo bag holds those bags until back to civilization. We also use a shovel and dig holes for waste.

Progress is slow, just as spare funding for it. Been a long hard winter for me, and barely any work to live on, let alone throw at this thing. Spring has sprung, and the work is picking back up, so the work is & will pick back up on this.

I have managed to start gathering the major items needed for the water supply. I built a cardboard box using the tank measures, for mock up purpose. I settled on a 30 gallon potable fresh water tank, and 3.0 gpm instant on 12v pump. 20 & 25 gal tanks are not much smaller in size, so 30 it is. Those are on the way, and a week or so out. I am currently researching on what type of plumbing I want to use for it. Pex lines are cheap, sturdy and easily available, it's just all the connectors that are costly. I would use Shark Bite push to connect fittings if I did this. Pex is not pliable, so any turns require elbows, at $10/ea. A simple Pex shut off valve is almost $25/ea. I added up over $150 for most of them, and compared to brass fittings, or even plastic, Pex is 5 times higher. Figuring out the routing, fittings needed, all has to wait until the tank & pump are mounted.

For the heavy filled 250 lb tank, a good solid mount is needed, but not that easy as it might seem. I have planned on using sections of 3" angle iron bolted to the flooring on both sides of the tank, then single E-Track strap mounts, and ratchet straps securing it over the opposite sides of the angle. This will lock it in place side to side, and front to back. It will rest on 60mm rubber membrane.

Gravity fill 1.25" ID tube routed to the cabin wall, and a 3.5" hole cut, then a gravity fill spout with screw on cap installed. This spout dealio also has a mesh screened vent hole and barbed nipple for a 1/2" vent hose to the tank. Supply lines will be plumbed to the front and the rear of the trailer, with an inline shut off valve for each. 1 for the hot water heater, and 1 for the kitchen use. The heater can be used with 30-80 psi from the pump. The pump I got has 45 psi, but can adjust a bit +/- psi. I have to figure out a good mount for that pump close to the tank still. Same with wiring and switch location. I want to keep the switch inside the cabin to prevent accidental activation.

The kitchen slide out and storage slide out are still being planned out, as I keep changing it up as I research parts/methods for the build. Some ideas look great on paper, but not so great on real world applications as parts are non existent, too hard to fabricate, or simply wont work for this or that. I'm super close to the final draft tho.

The vinyl graphics have been worked on for months now, and has been finalized, and ordered. Going to be some time for those to go on tho. Have to finish the build, then clean & polish wax the entire cabin, and boxes prior to install. The themed graphic design & color is subtle. Just enough to give it a nice contrast, but nothing annoying and yells at you like a billboard.

Oh, I did build an aluminum shelf for one of the front side box compartments. lol
 






The "digging a hole" can turn into digging a grave depending on how long and how many--just sayin' . After 4 people and a week, the 'loo bag turns into a body bag only worse.
 






The "digging a hole" can turn into digging a grave depending on how long and how many--just sayin' . After 4 people and a week, the 'loo bag turns into a body bag only worse.

LOL, yeah, we know this from first hand experience, don't we. :D
 






Eww Jon, tmi:fart:

Gregg that really is impressive! I wish I had a tenth of those skills
 






Limited Supply Environmental Protection Wash Basin Sink 5 Gallon Portable Toilet Flush Wastewater Recycled for Car, Boat, Caravan, Hospital https://www.amazon.com/dp/B07CT9G61V/ref=cm_sw_r_cp_apa_i_m2AMCbDAXMBFP

Umm... wtf?

Now hold on a minute. Did you see that thing? It is very cool, and I think you need to incorporate one of those into the build. Then you can say you have everything, including the kitchen sink.

EDIT: If you scroll down the link page, there is the "ala carte" sink and commode separate, and they total out to $138.
 






LOL, no thanks. I did look at it.

While this trailer does have some amenities to it, it is still not full on glamping with an RV. As stated in the very first post, this leaves some of it on the roughing it side of camping.

I have a brand new Cabella's double sized shower tent, and the folding stool already, and that is far more than needed as is. :)
 






LOL, no thanks. I did look at it.

While this trailer does have some amenities to it, it is still not full on glamping with an RV. As stated in the very first post, this leaves some of it on the roughing it side of camping.

I have a brand new Cabella's double sized shower tent, and the folding stool already, and that is far more than needed as is. :)

That commode/sink combo would fit nicely in that shower tent. I have a nice RV, but I do enjoy tent camping as well. Tent camping puts you more in nature whereas RV camping puts you on top of it. It all depends on where, when and who is going.

It would be kind of fun to pull that out of the Explorer and have a nice sit-down in the middle of the Mojave Trail.
 






Lol, that would be a funny sight to pull up on that scenario.

I'm fighting for every sq inch of room inside and outside of this as is. No room for what I already own for camping now, let alone add something as bulky as that thing. Lol

If a lady has an issue using what I offer for doing the biz, then she is SOL!! Us men will be happy with a wind screen, and the NY times, to clean with.
 






The good:
Water tank & pump showed early. Can finally start fabricating the brackets for them. :)

The fill tube and supply tubes that came with the pump, are weak sauce tho. No wonder they said it was a free kit included. Lowes has some good reinforced tubing, sold by the foot. Need to find some decent clamps too.

The Bad:
Bought a nice 40k btu 2 burner High altitude Camping stove on Amazon. Price was lower than anywhere else I seen this unit, so I snagged it instantly. 4 days later, I get an email from the seller saying, they refunded my $$, and the reason was due to "Account Adjustment" .... WTF!! I wrote them and asked for a detailed explanation. I knew what they did. They screwed up and posted the wrong price, seen it with my order, then cancelled the order so they didn't have to honer the advertised price. I checked the item again, and yep, sure as snot, they raised the price. Scumbags. I even paid for an extra 2 yr warranty for it, but since that was from a 3rd party, I didn't get refunded for that. I looked, but couldn't find a way to reach out to Amazon about it. Sigh...To good to be true thing I guess.

The unknown:
I want to add quick disconnects to the front shower supply line. The only thing I can think of for this is high pressure hose fittings, like for power washers.These discos can be seperated, and keep the water pressure held in the line, just like air line connectors. Reason for wanting these is the 2 fold. 1) Stainless bearings. 2) larger 3/8" ID. Air line connectors are a small 1/4" ID and restrict water flow, plus bearings rust with moisture. Some high grade auto type have stainless guts, but the ID is still too small.

Problem with this is the supply line is 1/2" tube, and the heater end is 3/4", same as garden hose. I have only found those discos in 3/8 NPT. Need some conversion fittings for this to work. A bulkhead fitting in a side wall, with the disco outside for easy access, then the supply line tucked away neatly inside, permanently mounted.

C'mon Google Foo!! Don't let me down!!

Edit: Google foo foo for the choo choo, resulted in me learning that I was thinking of the wrong type of quick disco's. The power washer style are pass threw, no stops. I need Industrial Hydraulic line fittings with either a ball or poppet style valving. There are so many applications for this style it's mind boggling with the number of combo's offered. I will have to talk to one of the companies to help figure which is best for my application, after giving them all my specs, want's, & needs.
 






I would send the seller a message complaining to them about their poor business practices and threatening to complain to Amazon. Tell them they owe you whatever it cost for the extended warranty.
 






I got an automated response email from amazon about my email to the seller. It says they have 48 hours to respond. Not sure what happens if they don't. Hopefully Amazon steps in and helps out. If nothing becomes of it, then I will attempt to get a refund for the warranty. If they say to bad, then I will do as you say BKenendy, and reach back to the seller about it.
 



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You can’t cancel the warranty? I had a warranty on some headphones and was able to cancel it up to 30 days after purchase. I actually intended to use it but “returned” the warranty instead of using it.
 






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