Expedition trailer made from FJ40 tub

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Man the whole package looks sick.
Thanks! It was so rewarding to get it out in a real trail enviroment (even though I was only 2 miles from home :D), and see how it behaved in a variety of situations. Ive had plenty of experience on road, but I'm new to pulling a trailer on a rough trail, over boulders, and ruts, etc. I hope to get in some more practice runs over the winter as I continue to work on the inside guts. I am currently putting together a multi-day off road adventure for the the spring with a few of my friends who own 40's. Hopefully by then I can have any potential bugs worked out.

Ive just recieved the stainles hardware and drawer pulls for the kitchen. Also bought a small 12v heater to test out.
 
Great photos! What tires are you running on your stock steel wheels? Size?
BFG 33X9.50's all around on trailer and tow rig. The idea is interchangability.
 
That wheel/tire combo looks perfect!



BFG unfortunately no longer makes either the AT or MT in that perfect size, from what I can tell in my recent tire searching.
Yep, all these tires were purchased used. Thats the main reason for the mismatched MT's and AT's. Had to take what I could get in that size. At some point they will wear out and I will be forced to buy something wider, but I really love the tall skinnies. Im a big fan of the retro stock look.
 
Here's a photoshop idea I played with...

I really like this idea. Or, lose the top and windshield, put half doors under the lid.
 
Slowly continuing to make progress. Not much that is photo worthy. Ive been working on the mounting tabs for the skin material on the kitchen. Kind of tedious work. The tabs (35) are 1/8" steel made from a 6' X 1-1/2" strap. Tapping each one by hand. Almost ready to start welding them in.
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First 2 pics are of a welding jig that I made to hold the tab in the precise position for welding. third is my drill press all rigged up for mass production so I can have some consistency on fastener pacement within the tabs.
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I have'nt done anything with the trailer since the last post. I have been chipping away at my list for the FJ40 in preparation for a noew years day run. - However, the long awaited sink finally arrived and it fits like a glove! These initial pictures dont do it justice so I will take some more later, but I am very pleased. the cutting board and drying rack accessories are awesome and stow in the sink basin.

I also bought a 4' X 8' X 1/4" sheet of birch plywood so I can start cutting out the skin pieces and finally get this thing fleshed out. :clap:
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January was a rough month work wise, so no progress. Then my wife had a baby so I took a break from work. In between helping with the kids and new baby, I made some progress. First, I have been mulling over how to distribute propane to the various apliances that Id like to run. Then I had an Idea. There is a void behind where the cook stove sits. It occured to me that I cound mount a propane distribution tree inside on a hinge. when in the vertical position Ill have 4 propane ports. 2 down low in the cabinet, which will feed the cook stove and an aux. (for an oven, or a dutch oven burner etc., see pic.), one mid mast, (still need to make the tee) that will supply a small radiant heater for winter camp, and of coarse a lantern on top of the mast. Seemed like a good idea, so I bought the Mr. Heater distribution tree and modified it to suit my application. Ran into a little difficulty converting the throw away bottle fittings at the base of the tree to a flare fitting because threads were an odd ball size. Had to drill and tap, but managed to get it worked out.

Since there was an unused space, I have installed 22" full extension drawer slides in between the giant slides to hold a flat platform that pulls out the end of the kitchen. This platform will hold a propane oven, or dutch oven burner, or fridge, or food pantry or........ Im sure it will come in handy.

I have also welded in all the tabs that the 1/4" plywood skin will attach to. Just have a little more strap to weld in for the interior drawer slides to mount to. I have the slides, and they are self closing, meaning they stay closed and require about 9 lbs. of pull to let go and come out. this is so the drawers don't come out inside the trailer while im going down the trail. They are pretty slick.

I have some pics. The wood pictured is just the prototype wood, not the plywood that I will end up with.
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More pics. Lantern is a mini coleman single mantle. perfect for this application. Dutch oven burner top is pretty close to counter top hieght.
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Here is a shot of the mounting tabs. One of these in every corner, and some in the field on the longer panels. Thats a whole lot of cuts, drilling and tapping.
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Congrats on the new baby and the progress looks great on the trailer!

-Daniel Kent
 
I got all the "skin" panels cut. still have to drill and counter sink mounting holes and a little more work on the frame. After that, I'll build some drawers. Then it's paint and seal time.

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Stumbled across this thread... Awesome Trailer.
 
Bump for progress update. :)

-Daniel Kent
 
I do have some updates coming. Mostly I have been working on clean up welding. But this week I hope to have kitchen installed and tent material hung.
 
I took the trailer out on our clubs big trip last weekend exploring the Arizona strip. Although far from complete, I did manage to put together a prototype tent so that i had some privacy in the sleeping compartment. Trailer was completely loaded with everyting i could think of to bring. I was impressed with the amount of cargo space. This was the first real shake down trip for the trailer. I was impressed as were several of the club members with its off road ability. It tracked behind the 40 beautifully. I could certainly tell it was there, but it wasnt too much of an anchor.
Unfortunately I discovered some cracks in the frame where I had joined the fj40 frame to the tongue that will need to be repaired and reinforced. The wires for the lights were routed in a way that they got pinched. Other than that I was super encouraged. The red strap is there because it was windy and the tent material is not secured to the tub yet to hold the top on. It got me really excited to finish up the project so I could take it out again! Here are some action shots:

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A couple more. Here you can see the shower/toilet tent.

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