Adventure trailer build thread.

Rated "I/A" for Immature Adult content! Stop, and close this page if you can't handle Silly, foul, and obnoxious adult content!

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!

First real use!

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.

 

[BKennedy]

Don't look at it for a few days, then jump back in.
I didn't name the boat either, its still "that fast as hell 502 jet boat" when its spoken about. Never really talked to the boat, well maybe I did when it didn't want to start out on the river ten miles from the dock.

 

[BKennedy]

I just thought of a name for the trailer; Best Girl. She is sexy, doesn't mind getting dirty or a little scratched up, and will follow you everywhere.

 

[gmanpaint]

That's the definition of a keeper! Lol

 

[gmanpaint]

Went back at it on Sunday. Out in 14 hours on it over the weekend. Put in another 20 hours on it so far this week. Doesn't seem like I accomplished much, but there is progress none the less. Did I mention, I ain't fast, but... I sure am slow.

Managed to get the screw up with the interior brackets cut off and re-welded an inch lower. Dremel has upped their game with the EZ lock cut off wheels. They are as strong as the larger ones for angle grinders. I used the 1/2" belt sander to grind the welds flush, then the dremel to cut and finish them welds off. Here is one of them. I tried to protect the white paint as best I could, but I still have to touch it up. Smoke and grinder sparks mostly. The black paint I ground off is simple, just brush on some POR15, and done.

Using the come along on the rafters, I used long bolts to hold the box on the main box. This allowed me to pull the straps out from behind, then swapped in the right size bolts. That was Sunday. Not a Funday. I was wrecked. Back and legs are actually bruised up. lol

So on Monday, I started to trim the Dr side box. Did a bunch of head scratching, cut some aluminum angles, and using 3m auto badge tape, got that box done. That took me all evening.

Fast forward a day, and realized I had a made a mess of this thing, and spent a couple hours with the air gun and shop vac. Lots of metal bits in all the nooks from working on it. Decided to lay some beads of black silicone on the interior walls and lower frame rails. Sealed it right up, and let it set up overnight undisturbed.

We are now at the present on Wednesday. For you reading this, it is already the past. Catch up slacker, jeez.

Grabbed the drill, and put 12 holes in the trim, then added rivets, to keep them in place. Another mess to clean....sigh.

Put the door insulation on, then the doors. I need to get some 1/4" insulation, as the 3/8" is just a smidgearino too big. Doors shut, but are tighter then I want, and the 3/8" is forcing the doors out a bit, not letting them be flush to the edges.

Added some Battery operated switched Leds. 2 in the main, 1 in the front compartment. 270 Lumens each, held on by large velcro patches. If I leave one on by accident, I only drain the AAA batteries, and..... no wires to run. lol

Put in the strap tie downs. These are adjustable, and can move side to side across the box. I am going to cut these 1/2" eyebolts down a couple inches eventually. Left the right ones off, so you can see the special nuts used in the unistrut channels. You push them in after loosening the bolt, then slide them where you want, re tighten the bolts by hand, good to go again.

Installed some chains on the doors. Small door, the chain is small, and only meant for a stop. The bigger doors however, they got some beef chains to hold the doors flat, when opened. These will be used as tables for various things. I am going to line the back sides of these box doors with something, probably 5 ply 3/16" Baltic Birch. That's down the road tho. These doors should be able to hold 50 lbs easy.

Front compartment done

Main compartment almost done (minus shelf, floor,and door liner).

So that's it, 20 hours for all that, and haven't touched the pass side box yet. Needless to say, it's going to be a few days before I have another update. I lost track of how many hours are wrapped up in these boxes, but I would guess a ....... A LOT! Started them last February or so. Yeah, getting these things on is a small victory for me, and I'm still not done with them! smh..... something wrong with me.

 

[WormsExplorer]

This thing is looking awesome sir.

 

[gmanpaint]

This thing is looking awesome sir.

Thanks a bunch. Won't be long. Before it's pulled out of the shop and I can get some full pictures of it. It's looking like something now.

Oh, played hookie after lunch, and spent 5 hrs getting the pass side box done.

 

[gmanpaint]

Another weekend, another update.

Picked up some Birch & Red oak, and got to use my rip saw attachment. Pretty cool gadget, that takes the place of a table saw. Slapped on a fine 60 tooth blade and cut some stuff up.

Had to use a jigsaw, drill, orbital sander, dremel with routing bits, to make these. Got everything fitted, and installed with custom brackets, then took it all apart, and stained everything Red Mahogany. Sticking with the classic color choice here.

Sidebox get 1/2" Birch floors & shelf, & 1/4" Birch door skins.
Tongue box gets 3/4" Red oak shelf, and 1/2" Birch wall panel.

Letting it all dry for a day or 2, then I will begin sealing, sanding, & clear coating, (There is a couple pcs missing in this pic, as they are drying elsewhere).

More materials arrived today, and more coming tomorrow. Getting things at hand done, planning for the next step after, and 3-4 steps ahead, while remembering to go back and do the things that had to wait, until something else was done, can be mind melting. Big reason post so much in details, is not only to share, but to help me remember! lol

Stay frosty!

 

[Turdle]

That is some good looking wood.

 

[gmanpaint]

5 coats of Spar Urethane later....

 

[gmanpaint]

All wood is installed. Stainless hardware is all recessed, except the door skin brackets.

Tongue box

Pass side box

Dr side box

I am on the hunt for wood screws for the skin brackets. They have to be SS #10 panheads, and no longer than 1/4". They are clamped tight now, but will feel better with them screwed on there.

 

[Turdle]

If you pre drill the holes you could cut 1/2" screws to length with a bolt cutter. Just an idea because 1/2" screws should be easier to find.

 

[gmanpaint]

Thanks Jon.
If I can't find what I'm after, I will keep that in mind. Dremel cut off wheel works pretty good for that.

 

[Spudhut]

Great work, awesome trailer.

 

[allmyEXes]

Wow ! This is the first I've seen of all 6 pages of your build. Excellent work ! I saw mention of possible names and one that I read made me think of one..."Black in Back". A turned around Back in Black. Just an idea. Acronym BnBBOT..Black in Back Bug Out Trailer
I'll be following along.

 

[gmanpaint]

Thanks for the props, and the suggestion.

Another weekend, another...... well, you know.

I went after the interior flooring. 3 months ago, I bought a full 4'x8'x3/4" pressure treated deck board. It takes this long (3-6 mo's) to dry out, sometimes more. This one was pretty wet/green when brought home, but the high temps sped up the dry time.

Knowing that the rear opening is smaller than the actual flooring is, it had to be made in a couple sections. I added extra floor brackets long ago, just for this. So with a bunch of in/outs of the wood......heh.... made myself laugh.....anyways, one pc at a time was marked and cut one edge at a time. To get the edges on top of the frame rails around the perimeter, it had to be notched for all the vertical box tubes.

Once all was made, and put in place, all the mounting holes was drilled from under, thru the bracket's 1/2" holes. Creeper worked perfectly for this, with 25" of clearance. Removed them, made the countersinks, and then sanded both sides. Back side just a simple knockdown, but the tops, was sanded smooth, and all marks/dirt/ink was obliterated.

That took about 6 hours yesterday, in the heat, with the vampire blood sucking insects, biting flies, ants wanting me for lunch, and these damn little sweat bees stinging the crap out of me. I look like I have chickenpox right now. Bug spray doesn't work, or they have become immune. Ugh!!

Today I started to put on the decking stain. Did one pc, and watched it dry to a nice freaking orange. Ok, 20 mins with the power washer removed it all. Can't touch this pc for a couple of days for dry time, and another quick sanding. Bummed...

So after searching thru a few piles of receipts and 1 hr later, I couldn't find the one I needed to return the natural cedar stain (puke orange). Day turned into a booger, and the biting bugs are still attacking. After coating my legs with clear anti-itch stuffs, off to the store I go. Couldn't find jack diddly to my liking at the big box store, and paint stores was closed on a Sunday. Hmmm....After stopping for a late lunch, I had a minute to think on this.

Ok, full belly, and feeling better, I decided to just do the flooring like the box shelving. I had enough stain left, just needed more Spar Urethane. Back to the big box store again. Set up the 2 dry sections that was ready to go, and got them stained both sides. Thats as far as I can go today, due to waiting on these to dry.

Floor section during power wash. Left some there to show the nasty color it dried too. Some of the grain just wont clean all the way, but not too worried about it. You can also see what the power washer does to it, and reason for another sanding needed.

All three after sanding

2 of them with the Mahogany stain on. Much better.

Guess I will power wash the concrete pad while waiting for this stuff to dry. lol

Parts boxes are building up waiting for install. I have to get cracking here!

 

[CDW6212R]

Beautiful wood finish. What do you plan to seal it with, maybe a polyurethane?

 

[gmanpaint]

Spar urethane. Made for exterior use, with uv blockers, and can handle freeze / thaw conditions. Same stuff used on the box shelving.

The grain really pops on these, I'm very happy with that.

 

[CDW6212R]

Excellent.

 

[gmanpaint]

4 heavy flood coats with a lamb's wool applicator made that grain come to life.

Need to let them cure out, and reach max hardness, before the next crucial treatment on them. This step is going to be a bear, but will help tremendously for longevity. It will be worth it.

 

[WormsExplorer]

Those look beautiful sir.