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Old 12-05-2011, 03:01 PM   #1 (permalink)
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Safari Pacific XT1 - Expedition Trailer

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.



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Old 12-07-2011, 09:11 AM   #2 (permalink)
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Old 12-07-2011, 11:02 AM   #3 (permalink)
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Old 12-07-2011, 05:55 PM   #4 (permalink)
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Old 12-07-2011, 11:31 PM   #5 (permalink)
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Looking good Travis.

Haven't seen you over on ExPo lately, hope all is well.
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Old 12-18-2011, 08:01 PM   #6 (permalink)
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Old 12-20-2011, 10:42 AM   #7 (permalink)
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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.
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Old 12-20-2011, 10:43 AM   #8 (permalink)
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The base chassis is 2 x 4 x 0.125 rectangle tubing. I went with 4 inches tall for added strength.




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




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






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

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Old 12-22-2011, 11:49 AM   #9 (permalink)
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Once all sections are cut and tacked into place I finish welding.




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.




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






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

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Old 12-26-2011, 01:36 PM   #10 (permalink)
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Old 12-27-2011, 08:20 AM   #11 (permalink)
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Demo of what I'm thinking. Room on the kick-outs for a 5 gallon fuel/water can or a 20 lb propane tank.




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




Ruff setup to check if axle is square with chassis.






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

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Old 12-28-2011, 05:42 PM   #12 (permalink)
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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?
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Old 01-10-2012, 10:13 AM   #13 (permalink)
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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.
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Old 01-10-2012, 10:14 AM   #14 (permalink)
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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.




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




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




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




Time for skinning.

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Old 05-22-2012, 12:39 PM   #15 (permalink)
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I start with the floor section and the front.




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




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




Then I move onto adding the skin to the lid.




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

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Old 05-22-2012, 12:41 PM   #16 (permalink)
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I like to over build. Good example is where the chassis tubes are split for the tongue.




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




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.

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Old 05-22-2012, 12:58 PM   #17 (permalink)
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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.



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

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Old 05-22-2012, 12:59 PM   #18 (permalink)
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I modified the spring plate to add a bit more strength. Also painted them and the other suspension parts.




Welded on the trailer jack attachment point.




Then began to spray primer.






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.

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Old 05-22-2012, 01:00 PM   #19 (permalink)
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I painted the everything the green color since I didn't want to mess around with masking the chassis off over welds.




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




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






Next I build the rear door.

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Old 05-22-2012, 01:01 PM   #20 (permalink)
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I use clamps to hold the door in place where I can mark where the door hinges will bolt to.




I drill the holes and bolt everything together.







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Old 05-22-2012, 01:02 PM   #21 (permalink)
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Welded on some shock mounts then finished painting underneath and inside the box.






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

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Old 05-22-2012, 01:03 PM   #22 (permalink)
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After the paint dried I attached the springs and axle.




Then set it down on some wheels and the jack.




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





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




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

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Old 05-22-2012, 01:04 PM   #23 (permalink)
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I added some carriage bolts to act as an adjustable stop for the door.




Rear door ready for paint now.




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



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Old 05-22-2012, 01:05 PM   #24 (permalink)
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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.





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

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Old 05-22-2012, 01:06 PM   #25 (permalink)
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Next I primer the lid and rear door.






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




Then I paint the hinges.




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

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