I've been hesitant to post up what I was doing with my free time now that I'm relatively free for the summer. I'm heading to CO/Moab/Ouray in early July and wanted to avoid the hotel costs. That rationalized buying the RTT I was sporting at the Spring Tide Ride. However, just that short trip with relatively little off-roading, I could easily tell how much having the 125+ lb tent on top would impact challenging terrain.
I'd already committed to building an expedition trailer through the purchase of a M416 trailer. Upon tear down of the trailer and planning all the necessary modifications, I came to the realization that it would be easier to just build my own, at least to make this summer's trip.
So goes it. With ~100 ft of 1.75"/.12 DOM tubing laying on the garage floor, a new tubing bender bolted to the floor, it was time to get busy and see if I could pull this off before I have to leave early July. With my ever faithful daughters as my extra hands, into the world of tube bending we go.
I know what you are thinking, why tubing? Why not? I started the whole adventure by planning on building myself a set of tube fenders for the FJC. I know how much I'd spend if I had someone else do it, what a hassle it wold be to borrow/get access to a bender that I again manipulated my lovely spouse to allow another tool purchase. Instead of going the "conventional" method of using square/rectangular tubing, I opted to be different, no surprise there.
Then, to top it all off, Greg came by so we had to spend some time discussing the project. He had to bring up what a great idea to use the top off a 40 for the lid of the trailer. Nothing like complicating an already time constrained build up by going from 4 90 degree bends to ones that would match the top off a 40 as well as the dimensions.
Here is the frame, bent from a single piece of tubing. Talk about reliving a bad geometry exam question. It seems simple until one has to start bending. I used some masking tape to help visualize the crossbraces...
Drove by Ramon's and picked up the top. Its in very good shape, kind of a crime (I'm sure some would say sacrilege) for me to have to section over 15" out of it to make a reasonable trailer. If I keep the track the same or just inside my FJC's, I couldn't really go wider than 48" for the tub. I marked the middle and the planned section that will be cut out...
Now, to lay the potential frame onto the top to see how well I did matching the shape/bends of the 40 fiberglass top...
Catching the right spot for the 5 degree bend to the front was a lucky shot in the dark...
The frame on jack stands, cross braces welding in place, pile of uprights ready for tacking into place so the top of the tub can be put in place...
Uprights tacked in place, top of the tub being tacked onto them. Regina came out to get some actions shots...
Finishing up the welds with the tub ~90% done.
I got the "Lock-N-Roll" hitch and coupler in the mail on Sat so I need to make another trip down to see Shep @ Fabco for 60" of 2X2 square tube for the tongue. Then I can finish that up and get ready to section the top to fit the tub. I've already got the glass/epoxy/top coat to put it back together once I cut out the 15 or so inches. Then, its got to wait until I get back from a professional conference in San Antonio. Upon my return, I'll only have about 10 days to finish it once I get back. Nothing like putting pressure on myself...
I'd already committed to building an expedition trailer through the purchase of a M416 trailer. Upon tear down of the trailer and planning all the necessary modifications, I came to the realization that it would be easier to just build my own, at least to make this summer's trip.
So goes it. With ~100 ft of 1.75"/.12 DOM tubing laying on the garage floor, a new tubing bender bolted to the floor, it was time to get busy and see if I could pull this off before I have to leave early July. With my ever faithful daughters as my extra hands, into the world of tube bending we go.
I know what you are thinking, why tubing? Why not? I started the whole adventure by planning on building myself a set of tube fenders for the FJC. I know how much I'd spend if I had someone else do it, what a hassle it wold be to borrow/get access to a bender that I again manipulated my lovely spouse to allow another tool purchase. Instead of going the "conventional" method of using square/rectangular tubing, I opted to be different, no surprise there.
Then, to top it all off, Greg came by so we had to spend some time discussing the project. He had to bring up what a great idea to use the top off a 40 for the lid of the trailer. Nothing like complicating an already time constrained build up by going from 4 90 degree bends to ones that would match the top off a 40 as well as the dimensions.
Here is the frame, bent from a single piece of tubing. Talk about reliving a bad geometry exam question. It seems simple until one has to start bending. I used some masking tape to help visualize the crossbraces...
Drove by Ramon's and picked up the top. Its in very good shape, kind of a crime (I'm sure some would say sacrilege) for me to have to section over 15" out of it to make a reasonable trailer. If I keep the track the same or just inside my FJC's, I couldn't really go wider than 48" for the tub. I marked the middle and the planned section that will be cut out...
Now, to lay the potential frame onto the top to see how well I did matching the shape/bends of the 40 fiberglass top...
Catching the right spot for the 5 degree bend to the front was a lucky shot in the dark...
The frame on jack stands, cross braces welding in place, pile of uprights ready for tacking into place so the top of the tub can be put in place...
Uprights tacked in place, top of the tub being tacked onto them. Regina came out to get some actions shots...
Finishing up the welds with the tub ~90% done.
I got the "Lock-N-Roll" hitch and coupler in the mail on Sat so I need to make another trip down to see Shep @ Fabco for 60" of 2X2 square tube for the tongue. Then I can finish that up and get ready to section the top to fit the tub. I've already got the glass/epoxy/top coat to put it back together once I cut out the 15 or so inches. Then, its got to wait until I get back from a professional conference in San Antonio. Upon my return, I'll only have about 10 days to finish it once I get back. Nothing like putting pressure on myself...
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