Adventure trailer build thread.

gmanpaint · August 16, 2018

Been thinking about the name some, and so far I like Shadow, and/or some kind a variant on this, ie...Dark shadow, midnight shadow, shadow mule, etc... This is not written in stone, just pondering on it is all. Kinda seeing if it grows on me or not. lol

Been raining hard here lately, and been working a bunch, so not much to report on here. I did manage to make a gasket for the switch panel. It didn't come with one, or I lost it. IDK! So I bought some dense foam gasket making material sheets of the old Amazonian parts getter site, made a template, and cut it out. Worked like a charm.

Will be back at it again this weekend. As if I have a life anymore, and would do something else!

Gotta get that choo going again here, as days are getting shorter now.

CDW6212R · August 16, 2018

I like it, the name Shadow, or half of a good name. It'll be like a rolling back pack, a supply shack etc. IDK either, keep pondering.

gmanpaint · August 18, 2018

What is this Loco Gringo doing now?

allmyEXes · August 18, 2018

Making bottle holders ?

allmyEXes · August 18, 2018

Looking good !

gmanpaint · August 18, 2018

allmyEXes said:
Making bottle holders ?

Nope!

More on this tomorrow, stay tuned.

gmanpaint · August 19, 2018

That 9-5, M til F thing turned into weekends for me too. Wasn't able to complete what I wanted to all the way, but got 70% done.

Anychoo... Now that the floor was built, and the tops was sealed up, the bottoms needed it as well. Stain used was Minwax, and it has a sealer in it, then a couple coats of the clear was also used, on the sides and bottoms, but that wasn't enough for me.

To really seal it up, and take the abuse of traveling on/off road, I used 60 mil commercial fleece backed TPO roofing membrane for the bottoms. I had a left over roll, from a past job, so it worked out perfectly. Pc's was cut to size, notched/trimmed, and adhered with a contact cement. That picture of the propane tank, is my redneck pressure roller. For roofing, we just use a short stiff bristle broom to work the material into the adhesive, then use a 25 lb roller to work seams, then heat weld. I didn't have the roller, and the propane tank weighed 28 lbs, is round, so why not?

Got all the bottoms done yesterday, and the edges worked on today.

Glue on the edges setting up before the material can be wrapped. Tape to protect the tops, from adhesive on the sides.

The rear main compartment flooring is on the rack drying overnight, and will get installed another day. I wrapped the edges of the boards, then taped them to the face, to hold them until the glue is completely set up, and cured.

This front pc, I didn't glue to the board edges for a reason. These will be sealed to the trailer walls instead, forming a nice tight barrier to the outside.
I did this one the day before, and it was ready for install. Fastened to the frame tabs with 1/2" carriage bolts, washers and stop nuts, all stainless. (don't look at the lawn mowing shoes!)

Shot from underneath showing the TPO. This stuff is durable, cleans fairly well, and is weather tight.

I had a bit of a time with the carriage bolts. These sink into the wood when drawn tight, and grab for a no spin. Well, one of them the recess hole was filled with clear or just wasn't big enough, so it wouldn't grab, and just spins. I need someone to apply pressure to it, as I work the impact on the nut. Fight for another day. Once these are all installed, I can start the next step.

That's it for this weekend ladies & germs.

Oh... How does Midnight Shadow or Night Shade sound?

CDW6212R · August 20, 2018

I like that Midnight Shadow, but both are very good.

gmanpaint · August 21, 2018

Another little Milestone. The rest of the flooring is installed finally.

Had to rework the holes in both the flooring and the mounting tabs, as the TPO is 1/8" thick on the edges. 2 edges =1/4", 3 edges=3/8", etc...

Got it all taken care of, and they are all now bolted in nice and secure. I had one seam between the front & middle, that had a tiny gap, so I used some stiff metal backed tar tape to seal it off from underneath, to the frame rail. We use this stuff when installing new windows. Amazing stuff, but crazy expensive. I just happened to have a new roll of it, left over from a job.

Inside with divider wall removed.

Underside showing the tar tape. This stuff grabs, and sticks great when it's warm out. Once it sets up for a couple days, it will be some work to remove it. But, that's a good thing.

Getting closer & closer to being something. Woot Woot *****'s!!

WormsExplorer · August 21, 2018

Love how the floor looks.

gmanpaint · August 26, 2018

Personal CRS Electrical reference post: Cuz I'm so old, I remember when Rainbows was in Black & White. Gotta write this fodder down! Filling in as I go.

7 wire J box:

IN> White = Ground 8 ga ................... OUT> Black 4 ga ..........TO> Frame
IN> Black = Battery Charge 8 ga ........OUT> Red 8 ga ............TO> Tongue box Battery
IN> Yellow = Left turn.......................... OUT> Yellow ...............TO> Left Turn
IN> Red = Aux.................................... OUT> White...................TO> Reverse
IN> Green = Right turn........................ OUT> Green..................TO> Right turn
IN> Brown = Running/tail/tag.............. OUT> Brown .................TO> Running/tail/tag
IN> Blue 14 ga = Electric brakes ....... OUT> Blue 14 ga ...........TO> Brakes

Tongue box:
115v 2 bank 20 amp smart battery charger> 110Ah Magm Dual batteries =220Ah
2000w power inverter>
Solar battery controller/charger>
12 circuit 12v Bluesea fuse block>
100 amp circuit breakers x2> Fuse block /Fridge
100 amp safety switch x2> Fuse block / Fridge
100 amp fuse> Tow rig Alt charge wire
120v outlet for battery charger/inverter, w/cable door

Tongue box out:
100 amp breaker- Red 4 ga...........To> 12v Fridge/Freezer
4 awg grounds (2 ea)..................To> Frame
Control Panel:
Breaker # 1..................................To>Roof 18W Led pods (4ea)
Breaker #2...................................To>Undercarriage 10W Led pods (4 ea)
Breaker #3...................................To>Awning Led power
Breaker #4...................................To>Main box Led Dome lights
Breaker #5...................................To>Side doors power
Breaker #6...................................To>Rear door power
Breaker #7...................................To>T-box usb port
Breaker #8...................................To>T-box 2000w inverter
Breaker #9...................................To>T-box 12v outlet for 1mil CP handheld spotlight
Breaker #10.................................To>open

Front Compartment:

Main compartment:

Left & Right side boxes:

Roof:

Undercarriage:

Tent:

Awning:

gmanpaint · August 27, 2018

Not much spare time to work on this thing over the last week. Too hot and humid, to want to work on it much either.

Got strap points welded on all 4 corners of the trailer, etching primer, and some simple rattle can paint for now.

Mounted and wired up the J-box. Had to remove the tongue box for this. Yay! (not). Cable is strapped to the top of the tongue rail for safety, tucked under the expanded metal, and ran to the box. Box is mounted to the 1/4" AR plate, and grounded to the frame via 4 ga, Out wires come back thru the expanded metal, where eventually will be tied into everything, and ran inside some 3/4" flex conduit.

Decided to do a mock up of the interior 1/2" electrical conduit. Glad I did, as I need to make some changes. Have to replace all the 90* elbows with gradual 90* sweep corners, and 1/2" J-box's. Reason being, is fishing the wires past those 90* corners, will be a PITA, even with a flat fish tape. I could make it work, and put the conduit together as I run the wires, but if I want to add a circuit down the road, it would have to come apart. Meh...

I am going to wait until the temps are bearable to be working inside this thing. Pretty sure I am going to install a vent fan. I didn't think of the interior temps until I was laying inside this thing, and felt like a a turkey in the oven.

Until next time,..... don't forget to tip your Banana mechanic.

gmanpaint · August 29, 2018

Rain day!! With today's gully washer, I had some free time from work. Stuck inside, I quickly wrapped up my paperwork for the day, and headed out to the shop. Hello Beautiful!! Heh heh heh....

Anywho... I picked up a few things from the hardware store the other day, and threw them on the trailer. The objective was to get wiring from the tongue box, and the tow pigs wiring J-box underneath, safely into the main box. Sounds simple enough.

If you have been following along, and remember the details, I made this tongue box to swivel out, for spare tire access. It is nice and close to the tire (1" space), and utilizes the square footing, as all real estate on this thing, is at a premium. This means, the plumbing, has to be able to move with the T-box, as it swivels, yet stay securely in place.

The choice was made, over many burgers flipped on the grill, to use flex conduit, and watertight connectors. I had 1/2" stuff for this bought a long time ago, but after figuring out the amount of wires being used, and the mix of gauges used, I needed to go bigger. 3/4" is used. Doesn't seem like a 1/4" is much different, but it is 50% larger in the I.D.

Locations marked, and 1" holes was drilled with a step bit. Irwin step bit, not that cheap chinesium HF crap. Only the best for my baby!

This is one of the watertight connectors. It has a nice rubber O-ring to seal with, and a NPT grab spanner nut to clamp with. After the flex line is inserted where you want, the collar is hand tightened.

I ran two lines into the box. The choice was made to have the junction inside the box, rather than on top of the tongue. Making the junction outside would have meant a clunky 3/4" 3-way J-box and very short flex lines, making it a tight fit, and I needed a loose fit for the swivel. Not to mention the raidus sweep for fishing lines. Wait.. crap, I mentioned it.

Both lines installed. Line coming out of the T-box will power all accessories. It had to be ran inboard a bit, to make the swivel angle when pulled on. Line coming from under the tongue, will power the trailer lights from the tow pig 7 wire box, plus the aux battery charge line. This line will be looped back from inside the trailer. Was the only blah point of this set up. Can't have everything man! The flex is strapped to the tongue tight, but loose to the t-box. Just needs a little play to move freely when the box is swiveled out. Straps will get paint eventually. Haven't decided if I want to bother with the PVC or not, as it will be a maintenance deal, once done.

Flex conduit installed to both boxes.jpg

Into the T-box, above the shelf, where all the lines will be coming from the devices mounted there.

Into the main box, where the junction will be made, and plumbed from there.

The Milwaukee Inkzall markers are made from octopus ass ink or something, it is hard to remove! I ran out of denatured alcohol, and 93% rubbing alcohol was useless. Everything else I have is too volatile to use, as it will eat the paint off.

Until next time..... Remember to send your wife's OBGYN a thank you card. It's a dirty job, but that's why they make the big bucks!

CDW6212R · August 30, 2018

I know how that goes, the brake cleaner and carb cleaner or too much for some things. Find some prepsol, a solvent for prepping paint/body work. I have a little left, and it works well for glue etc, but it won't melt plastic like brake cleaner can with some plastics.

gmanpaint · August 30, 2018

I have grease & wax remover I use for paint prep, it didn't touch this Milwaukee ink. Telling ya, it's alien juice!

CDW6212R · August 30, 2018

Okay, go get the carb spray! Don't.

gmanpaint · August 31, 2018

Can't wait until the first freeze. I can't take these Apache sized Skeeters any longer!

Pulled the wires for the J-box into the trailer, and buttoned that up finally. This meant I was ready to see if my plans worked or was a big fail with the swiveling T-box. Started this box months ago, so yeah, was kind of a big moment for me. With sweaty palms, and held breath, I swung it out to full lock.

Success! Look at, would ya just look at it? I mean, just look at that!

Swung to the Pass side

View from the Dr side

Ok, so after I began breathing normal again, I wrestled the 35" MTR into place. Got the theft slower downer dealio on too.

Tire is a bit dirty you say? No problem, on goes the Best Top cover. Closed the T-box, and it moved ever so nicely, smooth as a baby's bottom. Locked it down, and checked the clearance. Perfect! This train is Chooching now!

But wait! There's more!

Stood back and just let the view soak in. Had to wipe some tears of joy away, before the neighbors seen me.

Really starting to look like something real now.

CDW6212R · August 31, 2018

I love it.

For the bugs, do you have any cordless fans yet? I hate the skeeters, they love me, so I have a big fan at home I use while outside near the garage. I bought a Makita 18v fan last year that works great for portable use, anywhere away from home. Makita DCF300Z 18V LXT Cordless 13" Job Site Fan, Tool Only

gmanpaint · August 31, 2018

I have looked at the Rigid portable, and want it badly. I already have a bunch of the newer style Rigid 18v tools, with a bunch of batteries, and a couple chargers. Matter of fact, one of them chargers, is being mounted inside the tongue box.

I just do my best to move the 20" shop fan around as I work, but could use a bigger unit or another like it, to help. I do miss the 24" shop fan that recently died, that thing kicked ass for well over 10 yrs, before all the shop debris clogged the motor, and kilt it.

I'm also a skeeter magnet. 5 mins and some dime size welts all over. Hate it.

gmanpaint · September 1, 2018

Took advantage of the Chinesium store, Labor day sale with the coupons.

2500 # ATV winch, synnthetic rope swap, and wireless. Snatch block, straps and shackles (already own) will be stowed away.
This will be used for multiple things, and the big one, is to slide the ass end of the trailer, in the event of a tight turn to sharp to make the bend.

Making it removable with a hitch adapter I will build for it, and I happen to have a smaller group 28 MAGM battery for it, that can be mounted inside the trailer, and charged by a 3 bank charger in the T-box.

It will also double to assist in install/removal of the Roof Top Tent (RTT). This was cheaper than getting the 1500# chain lift for the rafters, that was planned for, and this takes care of that, when needed.

$95 out the door!!

Adventure trailer build thread.

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