My scratch built expedition style trailer build up thread

[REZARF]

60* and Sunny + a 1/2 day off and you have the combo to crank out the sheet metal today...

More pics later when I get done, I am going to finish both sides today which is HUGE!

[REZARF]

Today's progress!

Well, I started out by tracing the tubing onto the sides so I knew where I was supposed to drill for the rivets...

Then it was time to measure out and drill the 78 holes PER SIDE!

After the holes were laid out in the sheet, I lined up the panel on the tubing, checked everything a few times then got after clamping it down and drilling all the holes in the tubing using the sides as a jig. Not too bad, but lots of fitting and grinding, and shimming to get everything just right!

[REZARF]

Shim- I used a few pieces of scrap steel to shim the sides off the floor enough to leave a gap so I could go back in and weld the floor to the tubing as well.

Trim- I had a little fitting to do with the drivers side, I used a cut off wheel and a flap disk to get this edge to line up with the tubing. Not too hard but things like that really eat up the time.

Notch- I had to open up the 1" notches so I avoid grinding down all my interior welds. These weren't tricky you just have to stay in the right spot or you risk having a gap in your final sheet metal work.

[REZARF]

Now it was time to get messy and apply the Sikaflex... good stuff so far. Great tack/hold and lots of working time, it is a super product.

I cleaned all the mating surfaces with the rapid strip wheel, both the sides and the tubing, this should allow the adhesive to do its job well.

At this point know where your rivets and gun are, have some acetone around to clean up any mess and you just gotta go for it.

I leaned the sheet into place then started to fit about every 3rd rivet moving all the way around the side, then I came back and started to pop the rivets. After the sheet was in place by itself I began to insert all the other bazillion rivets and make quick work of them. As I type my back is sore from leaning over and I now have super human forearm strength from all the pop rivet action today!

FWIW, I ran about a 3/16" bead then spread it around with a disposable puddy knife before sticking the sheet to it.

[REZARF]

Sorry for the blurry pic, but it was the only one I took of the whole thing once the adhesive was on... no time to get artistic with the shot :hill:

And here is a shot of the panel in place after popping all 78 rivets by hand!

I cleaned all the seams with a bit of acetone and a few clean paper towels and I think it is ready for the next step, welding on the front panel and the floor.

[REZARF]

Not too bad so far huh?

Bring on CM08!

[jerz4wd]

Been looking at this for sometime now and want to say that this is very
well built trailer with alot of thought in it!!

I will try to get some pics of trailer that my son built in High School ag shop.
You can be very proud of this project

Jerry

[OkieRover]

I haven't been over here to see the progress since page 4.
OMG!
This is almost as good as watching Blog Cabin on the DIY Channel.
If you just had a couple of hot chicks running around getting some high angle shots while they work.


I have two questions.

Are you still married? (my wife would have left me by now)

Have you named your trailer yet?

If no I have a suggestion: La Otra Mujer
That's from the movie The Astronaut Farmer. I thought it was funny.

If you don't use that name for your's I'll probably use it for mine.

Anyway awesome job. I can't wait to see the drawers you are planning.

[REZARF]

Originally Posted by OkieRover

I have two questions.

Are you still married? (my wife would have left me by now)

Have you named your trailer yet?

Anyway awesome job. I can't wait to see the drawers you are planning.

Answer 1: YES! My wife is the greatest woman on earth, hands down!

Answer 2: No name as of yet. Maybe some day.

The drawers will probably be an addition after moab at this point, thanks!

Drew

[sseaman]

Drew, I am impressed. Looks like your ready for a field/rock test, it will give you a chance to tweak anything before its finished.

[REZARF]

Yeah, I hope to pull it in another 2 weeks then strip it for paint. However, I have to do more than tack the spring hangers on.

Thanks man!

[REZARF]

Sheet metal is ONE panel away from DONE!

Gotta fab up a tailgate this weekend... then time for a dry run.

Just had to share!

Drew

[Acadia]

Drew

you may have already mentioned this but what are you doing for fenders?

[LakeNorman_FJ40]

Suggestion? Buy some clecos & a set of cleco pliers to hold the sheet metal in place during drilling & riveting it to the tube &/or setting up the SikaFlex. Also, a cheap air riveter from Harbor Freight not only keeps your forearms from looking like Popeye, but also gets a super tight pull on each rivet.

Keep up the awesome work!

[REZARF]

Originally Posted by Acadia

Drew

you may have already mentioned this but what are you doing for fenders?

If you flip back a few pages I have bent up a set, just need to fit and skin them out, hopefully they'll be done this weekend, and I hope to have the tailgate frame out as well.

Thanks!

Drew

[Acadia]

Got it! Thanks!

Was there a specific reason why you decided to build the fenders out of tube then skin it rather than use a basic bent sheet metal fender?

[REZARF]

Strength for one, nor is my sheet metal break capable of building what I wanted. The tubing might weigh 5 pounds each side, which is nothing, when I can mount a shovel/hi-lift to and, and if the trailer flops the tubing should help out there as well.

Thanks!

REzarf <><

[REZARF]

Well, now that the sheet is on the sides I could get after the fenders and finish welding them up and knocking out the sheet metal part as well.

Here is what I started with this afternoon...

Measured the fenders, marked them in place, and drilled out the holes to mount them into the sides.

Then it was easy as bolting them up with my fancy bolts.

Then I squared it all up (it was only tacked at this point) and welded the seams in.

[REZARF]

I threw my welding blanket over the new MTR's... glad I didn't have to figure out that one the hard way

This is how I squared up the tops of the fenders by bolting them to a square

Then it was on to the sheet metal, which needed to be cleaned and prepped for the tube work.

[REZARF]

The sheet metal wasn't as hard as I imagined it might be, it took time to get it right but nothing was too difficult, I had to cut out a few tacks to readjust it once, all in all, not too bad.

The idea was to get the sheet square on the tube, tack the flat portion in place then start the bends as I moved the welds to the ends of the fenders. I found that if I didn't use the angle iron pieces the center would bow out in the middle making it sloppy looking, so after I added the L's into place everything smoothed out nicely. Then I just ran tacks down the inner edge of the fender, you can see how nice the curve matched the tubing... 6 clamps will do that for you

[REZARF]

Here is the shot of the inner fender before I tacked it into place...

After I repeated that on both sides, I notched the sheet in the places it needed to clear the frame and bolted them up for a look... really to step back and admire my work, it is a great feeling seeing it come together.

Here it is in place on the trailer.

[REZARF]

Here is how it sits on the trailer, I wanted full coverage so I don't get rocks to the back of the head in the 40, so I covered the tires entirely. I think they came out nice. I hope you like them... kinda, though, I don't really care

Just kidding, going to go after the tailgate tomorrow.

Rezarf <><

[chappysfj40]

wicked bad ass dude

[Acadia]

that truely is one impressive looking trailer!!!! you should be proud!