Burley Industries Prototype Expedition Trailer

[Burley]

Hello everyone!
I guess I'll start this thread off by introducing myself. My name is Jake Burley. I'm currently a dealership technician based out of Idaho, but my background is in production welding/fabrication. Over the past year and half or so, I've started taking on more and more welding and fabrication jobs with the intent of starting a side business. This leads into my current expedition trailer build. I've built a few trailers on my own in the past and even worked professionally at a few different trailer manufacturing plants. So when I set out in search of an expedition trailer to tow behind my FZJ80, I was blown away at the prices for what you get. So with that, I've decided to start on my own prototype expedition trailer. I've waited to start this thread until I was further along in the build just in case I through out parts of the design. I hope you all enjoy and feel free to leave feedback.

 

[Burley]

Here is the frame. It's made from 2"x2"x0.120" wall and is 4'x6'.

 

[Burley]

The rest of the box is built from 2"x2"x0.083" wall square tubing.

 

[Burley]

The lid I the same 0.083" wall tube.

 

[Burley]

For wheels I went with a used set of matching LX450. Tires are the take off's from my 80. I figured the trailer needed tires and the truck wasn't to much further down the road so I went with a new set of KO2's for the truck and that gave me four good tires that would last a lot longer on the trailer. This also allows the spare tire from the truck and the trailer to be able to be used for either.

 

[Burley]

Here is the lid with the cross members in.

 

[Burley]

Needing a place for a spare and a 5 gallon propane tank, i decided to add a two foot 'basket' to the front.

 

[Burley]

Something like this is what I had in mind.

 

[Burley]

I couldn't find a propane holder local and so I tried a few different thing but in the end they all looked to bulky and pretty goofy.

 

[Burley]

I went with weld on barrel hinges and a side opening position. After a lot of thought and research this seemed like the best solution to work in conjunction with my roof top tent.

 

[Burley]

I got it welded up and flipped off the welding table.

 

[Burley]

I went with a Dexter #3500 axle from my local Redneck trailer supplier. At 74" hub face to hub face it was the narrowest axle Dexter makes. When it came to axle placement I had initially wanted to add a 2'x2' compartment door at the front of the box.

 

[Burley]

Another initial idea I had was to be able to 'jack knife', or at least close to, the trailer. This is the reason for the long tongue.

 

[Burley]

So here it is in it's first iteration of total length and wheel base.

 

[Burley]

One more side view before the redesign.

 

[e9999]

nice job. Lid might end up heavy, looks like. What kind of skin will you use?

 

[Burley]

Here is the redesign of the tongue and the axle pushed forward almost 9"

 

[Burley]

nice job. Lid might end up heavy, looks like. What kind of skin will you use?

Thanks. The lid will be heavy but I have two #250 gas struts to help open the lid. I needed it to be stout enough to hold the RTT and my whole family. I don't plan to add anymore support to the front basket. The 'V' structure that runs under and ties it back into the main body should be plenty sufficient.

 

[Burley]

I decided on the 4B propane holder and I couldn't be happier.

 

[Burley]

I had a break in the weather and decided on a quick trip around the block.