I've decided to build myself an off-road trailer. Mostly to move all of my gear from both of my vehicles to one tow-able package. This way I don't need to swap things back and forth. And partly to build something cool again.

http://www.safaripacific.com/vehicles/xt1/build/051.jpg

http://www.safaripacific.com/vehicles/xt1/build/058.jpg

sweet. Subscribed. :D

sweet. Subscribed. :D

Subscribed:smokin:

Count me in too!

Looking good Travis.

Haven't seen you over on ExPo lately, hope all is well.

In ....

Looking good Travis.

Haven't seen you over on ExPo lately, hope all is well.

Hey Kurt, Thanks! Yep, all is good. I got tired of the bs and drama on expo.

The base chassis is 2 x 4 x 0.125 rectangle tubing. I went with 4 inches tall for added strength.

http://www.safaripacific.com/vehicles/xt1/build/001.jpg


Old Man Emu Dakar leaf springs from Sierra Expeditions along with hardware and led tail lights.

http://www.safaripacific.com/vehicles/xt1/build/002.jpg


I start by basic assembly of the suspension and axle. Then check for placement.

http://www.safaripacific.com/vehicles/xt1/build/003.jpg

http://www.safaripacific.com/vehicles/xt1/build/004.jpg


After I find the axle placement and distances for tire clearance I make kick-outs for carrying fuel cans.

http://www.safaripacific.com/vehicles/xt1/build/005.jpg

Once all sections are cut and tacked into place I finish welding.

http://www.safaripacific.com/vehicles/xt1/build/006.jpg


Then I move onto building the upper box. Since I didn't want to have the added expense of a one off custom sheet metal box I decided to make a frame to adhere panels too.

http://www.safaripacific.com/vehicles/xt1/build/007.jpg


Off the main box I run additional tubing to connect to the kick-outs for added strength.

http://www.safaripacific.com/vehicles/xt1/build/008.jpg

http://www.safaripacific.com/vehicles/xt1/build/009.jpg


Trying to determine placement of the truck oval led lights. I'm thinking I need to find something else.

http://www.safaripacific.com/vehicles/xt1/build/010.jpg

Subscribed

Demo of what I'm thinking. Room on the kick-outs for a 5 gallon fuel/water can or a 20 lb propane tank.

http://www.safaripacific.com/vehicles/xt1/build/011.jpg


Back to suspension. I had new parts cut out to get the trailers axle where it needs to be. High wise that is.

http://www.safaripacific.com/vehicles/xt1/build/012.jpg


Ruff setup to check if axle is square with chassis.

http://www.safaripacific.com/vehicles/xt1/build/013.jpg

http://www.safaripacific.com/vehicles/xt1/build/014.jpg


Once all aligned I weld up the parts and take the trailer outside to check hight.

http://www.safaripacific.com/vehicles/xt1/build/015.jpg

nice. i've been thinking of building my own as well. i can't imagine paying as much as those idiots on expo do for their bling bling trailers.

how much do you think it weighs?

nice. i've been thinking of building my own as well. i can't imagine paying as much as those idiots on expo do for their bling bling trailers.

how much do you think it weighs?

Yeah, they get pricey. Mines gotten expensive, not nearly as much as others but still expensive. Crap adds up fast.

Not sure. I'm hoping to be under 600 lbs finished.

Back inside I swap tires with the Ranger, since they are 32x10.5 tires. I wanted to check clearances and assemble the remainder of the trailer with larger tires.

http://www.safaripacific.com/vehicles/xt1/build/016.jpg


I also build the tow point similar to how I build Jim's hard side pop-up trailer.

http://www.safaripacific.com/vehicles/xt1/build/017.jpg


I then toss on the tent mostly for the hell of it.

http://www.safaripacific.com/vehicles/xt1/build/018.jpg


Next I weld in the floor cross supports, with one beam stronger to attach shock tabs.

http://www.safaripacific.com/vehicles/xt1/build/019.jpg


Time for skinning.

http://www.safaripacific.com/vehicles/xt1/build/020.jpg

I start with the floor section and the front.

http://www.safaripacific.com/vehicles/xt1/build/021.jpg


Then move onto the sides. I toss on a couple cans just because it makes for a cooler photo.

http://www.safaripacific.com/vehicles/xt1/build/022.jpg


Once the main body is welded on I start on building the lid.

http://www.safaripacific.com/vehicles/xt1/build/023.jpg


Then I move onto adding the skin to the lid.

http://www.safaripacific.com/vehicles/xt1/build/024.jpg


I take off the tires so I can finish up welding where the tires blocked.

http://www.safaripacific.com/vehicles/xt1/build/025.jpg

http://www.safaripacific.com/vehicles/xt1/build/026.jpg


I like to over build. Good example is where the chassis tubes are split for the tongue.

http://www.safaripacific.com/vehicles/xt1/build/027.jpg


With the trailer on its side I weld up all the small bits I couldn't get to from the top.

http://www.safaripacific.com/vehicles/xt1/build/028.jpg


Before I flip back over and set up on jack stands I use the pallet scale to weigh in. So far what you see is 390 lbs. Not too bad.

http://www.safaripacific.com/vehicles/xt1/build/029.jpg

In between doing the metal work I decided to start figuring out what color to paint the trailer. At the paint store I picked a color I though would look good. Turned out the name of the color was "money." The color swatch looked good at the store, though once back at the shop the color was brighter than I wanted.

http://www.safaripacific.com/vehicles/xt1/build/030.jpg

So I mixed small portions with black and brown to get something I like. I call the new color "dirty money"

http://www.safaripacific.com/vehicles/xt1/build/031.jpg

I modified the spring plate to add a bit more strength. Also painted them and the other suspension parts.

http://www.safaripacific.com/vehicles/xt1/build/032.jpg


Welded on the trailer jack attachment point.

http://www.safaripacific.com/vehicles/xt1/build/033.jpg


Then began to spray primer.

http://www.safaripacific.com/vehicles/xt1/build/034.jpg

http://www.safaripacific.com/vehicles/xt1/build/035.jpg


Next I sprayed on the green. It looks brighter in the photos, though is a more of a gray green in person. Might be the lighting.

http://www.safaripacific.com/vehicles/xt1/build/036.jpg

I painted the everything the green color since I didn't want to mess around with masking the chassis off over welds.

http://www.safaripacific.com/vehicles/xt1/build/037.jpg


After drying a for a couple days I attach the hinges lid.

http://www.safaripacific.com/vehicles/xt1/build/038.jpg


On the other side I attach over center latches. They have tabs that stick out to lock with a padlock.

http://www.safaripacific.com/vehicles/xt1/build/039.jpg

http://www.safaripacific.com/vehicles/xt1/build/040.jpg


Next I build the rear door.

http://www.safaripacific.com/vehicles/xt1/build/041.jpg

I use clamps to hold the door in place where I can mark where the door hinges will bolt to.

http://www.safaripacific.com/vehicles/xt1/build/042.jpg


I drill the holes and bolt everything together.

http://www.safaripacific.com/vehicles/xt1/build/043.jpg

http://www.safaripacific.com/vehicles/xt1/build/044.jpg

http://www.safaripacific.com/vehicles/xt1/build/045.jpg

http://www.safaripacific.com/vehicles/xt1/build/046.jpg

Welded on some shock mounts then finished painting underneath and inside the box.

http://www.safaripacific.com/vehicles/xt1/build/047.jpg

http://www.safaripacific.com/vehicles/xt1/build/048.jpg


The latch arrived today for the rear door. So now I can finish that up.

http://www.safaripacific.com/vehicles/xt1/build/049.jpg

After the paint dried I attached the springs and axle.

http://www.safaripacific.com/vehicles/xt1/build/050.jpg


Then set it down on some wheels and the jack.

http://www.safaripacific.com/vehicles/xt1/build/051.jpg


Next I plasma cut a hole for the latch on the rear door.

http://www.safaripacific.com/vehicles/xt1/build/052.jpg



I attach the door back on the trailer to figure out how to add a catch.

http://www.safaripacific.com/vehicles/xt1/build/053.jpg


I had an old cut out from another project that worked perfectly. 3/8 inch plate.

http://www.safaripacific.com/vehicles/xt1/build/054.jpg

I added some carriage bolts to act as an adjustable stop for the door.

http://www.safaripacific.com/vehicles/xt1/build/055.jpg


Rear door ready for paint now.

http://www.safaripacific.com/vehicles/xt1/build/056.jpg


I tossed some gear on the trailer so I have an idea on how to lay everything out and what brackets I'll need.

http://www.safaripacific.com/vehicles/xt1/build/057.jpg

http://www.safaripacific.com/vehicles/xt1/build/058.jpg

These are the led tail lights I decided to go with. The trucker oval style doesn't work well with my design of the trailer.


http://www.safaripacific.com/vehicles/xt1/build/059.jpg


I installed a standard electrical trailer j-box on the tongue. Now its to assembly and wiring.

http://www.safaripacific.com/vehicles/xt1/build/060.jpg

Next I primer the lid and rear door.

http://www.safaripacific.com/vehicles/xt1/build/061.jpg

http://www.safaripacific.com/vehicles/xt1/build/062.jpg


Then paint. It takes a few days to primer and paint since I had to wait for each side to dry.

http://www.safaripacific.com/vehicles/xt1/build/063.jpg


Then I paint the hinges.

http://www.safaripacific.com/vehicles/xt1/build/064.jpg


I use some off the shelf truck bed liner to coat the underside of the tent.

http://www.safaripacific.com/vehicles/xt1/build/065.jpg

During painting the lid I touch up a few spots like the rear door catch.

http://www.safaripacific.com/vehicles/xt1/build/066.jpg


A couple days later I coat the other side of the tent's underside.

http://www.safaripacific.com/vehicles/xt1/build/067.jpg


Then is on to final assembly.

http://www.safaripacific.com/vehicles/xt1/build/068.jpg

http://www.safaripacific.com/vehicles/xt1/build/069.jpg

http://www.safaripacific.com/vehicles/xt1/build/070.jpg

http://www.safaripacific.com/vehicles/xt1/build/071.jpg

http://www.safaripacific.com/vehicles/xt1/build/072.jpg

The last photos posted are from January 10th, 2012. On the 13th my dad passed away and the project was put on hold. Currently the trailer is in a friends garage in Mesa, AZ as I had to vacate the shop. I'm hoping this summer I will be able to bring the trailer out to my new place in Temecula, CA and finish it. There's really not much left. Ironically I'll have to trailer the trailer since there is no plate, lights or wheels. More updates to come once I get rolling on the project again.

Sorry to hear the news. Best wishes to you and your family. Really like this trailer. Small and simple. I really like those tents, been looking at a few of them. Still to pricey for me right now.