HOW I BUILT A CAMPER ON A 4x4 HARBOR FREIGHT TRAILER

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wilcoy02

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Here is my completed project. Still need a little adjustments-like weld a step on so I can get in it. I started this in late July 2014. Trailer was at the seamstress from Oct 21,2014 and picked up March 14,2015.

Hope you enjoy.


Here is how this trailer started out. $40.00 at a farm auction.
Starting out with a 4x4 HF trailer with working lights for this build.
First cut of Marine plywood. 47.5". x 39.5" for the base
Straight edge for saw to keep the cut straight
47.5" x 39.5" marine plywood base installed
Lay out the base. 1/2" from the edge for the exterior plywood side.
1 1/2" for the 2"x2" firing strip
2x2 attached to the base
Bottom side of base. Screwed base and 2x2's using #6 Square drive trim head 1". Glued the entire 2x2 with titebond III
Ready to saw the sides supports.
Saw looks good
2x2 cut into 12 pieces at 47.5" long
Closer view of the 47.5 2x2's
Head Supervisor moving some lumber
All the outside frame pieces all 2x2's
24- 6 inches
12- 11"
another view of frame pieces
I just like to look at a lot of sawed up timber
4 inch steel plate welded at 45 degrees for the left stabilizer jack attached to the trailer
Right plate welded to the frame for the right stableizer jack
First mistake-Should have notched the frame piece before putting glue on and screwing to the base.
Used a router to notch for the joint.
Tail end fitted together. 1/2" outdoor plywood cut 40"x 11.5"
Front side fitted 40 x 11.5"
Left side fitted outside plywood 48" x 11.5"
notice the frame pieces they are notched for a smooth side to screw and glue to.
The horizontal pieces are 47.5" and 39.5"
The vertical pieces are 11"
My first mistake is still haunting me as I have to notch the bottom frame in place.
The fourth side being put together using the 47.5" top and bottom rails and the 11" support pieces.
Three side panels in place.
The two ends are 1/2" outdoor plywood 40" x 11.5"
Two sides are 1/2" outside plywood 48" x 11.5"
Second compartment is waiting for the glue to dry.
I used the 2x2's for frame of the same size as the trunk of the trailer. I used 6" 2x2's for the spacers.
3 2x2 were placed the width of the trailer. This will support the 1/2" plywood placed on top of this box. On top of this plywood will be the compartment for the hardware of the tent. Hopefully the tent will be 38" x 90" and 4 foot tall.
Notice the coroner supports are not completed yet.
Three 2"x2" are place on top of the frame. They will be notched as well.
Using the previously cut 2" x 2" two 47.5" for the top and bottom rails
two 39.5" for the top and bottom rails
ten 6" for the supports which
are notched.
4th side being completed
Just look at all the wood yet to go.
All four sides are glued and screwed together. Gas cans are trying to straighten out the warped plywood.
Another view of the four sides completed.
Door cut so I can store stuff while stopped at the restaurant.
The paint suddenly appeared. I had to ride to Tom's Meet & Greet.
Construction of the top compartment, which will hold the tent, straps, and poles.
Notched the 2x2 and bottom frame support for the top compartment.
Sides are 6 inches high.
View of the front. The door with latch can be seen on the bottom compartment/trunk.
View of how to get things out of the trunk while the tent is opened. Tent not yet on.
Front view with all my stuff still packed from meet & Greet at Tom's.
Another view of the two compartments open.
Filling in the holes from the screws.
Filler of screw holes.
The top in place using 1/4 inch marine plywood.
Electric conduit being sized for the legs.
Have to see a pic of the front.
Other side of the platform.
Sleeping platform I used 1/2 inch plywood 42"x35".
A 42"piano hinge connects the two Pieces of plywood so that the outside piece folds upward.
Pneumatic shock
Pneumatic shock attached.
I used 2 80# pneumatic shocks to keep the two top lids open.
I placed a spacer in the 1x2 and put on a washer, locknut, and nylon nut.
Spacer in wood so it will swing opening and closing the lids.
The bolt and washer for the braces. And the stop block so they will only swing so far.
Brace in place. Did the same on the other side.
Stops to keep the braces from going to far.
Putting the braces in to hold the top compartment.
I used window catches for locking the top compartment to the middle compartment.
Sleeping platform out and I can still get in the storage compartment.
Three straps to hold the frame and platform.
I needed to know how tall this trailer really is.
YEP! I can still see over the top of it when I am on the bike.
I really worried about that point.
Some of the snaps to keep the tent in place.
Kitchen cabinet handles used for the hooks for the straps.
Hooks I made for easy on/off.
Fitting the straps for the support of the tent and platform
The sleeping area.
Can not forget the other side.
Side view.
Tent, frame, poles, all ready to travel.
You can see the frames and platform folded up.
Pic of all the straps now in place.
Pic of the straps and platform in storage position.
You can see the sleeping area.
Should be 3 straps.
The straps are attached to the frame of the tent.
The fly for the bike.
Other end of the tent. You can see how the straps work from the inside.
Inside the tent
Can not forget to cover the bike at night.
A picnic area when it is raining.
Front of the tent. Rainfly for the door is on top of the tent.
I finally get to go camping!!!!
Need to fine tune some things like weld a step on so I can get in the tent.
I hope you enjoyed looking at my build. Hopefully you may have learned something.
 
[url=https://classicgoldwings.com/forum/viewtopic.php?p=143450#p143450:3bp00vvv said:
brianinpa » Mon Mar 16, 2015 9:52 pm[/url]":3bp00vvv]
Wes, just curious if you know the total weight of the trailer yet...
+1 :yes:
 
It looks kewl, but I gotta question this statement...

wilcoy02":kcacb9es said:
image.php

Notice the coroner supports are not completed yet.

Is there something you're not telling us? Should we be worried? :smilie_happy: :mrgreen: :smilie_happy:

I'm also curious about the final weight of the rig. Good Job, tho!! :clapping: :good:
 
I put the captions on the top of the pic so you have the caption to the pic above.
No I have not had the trailer weighed as of yet. Will do in the near future.

The coroners I wanted to make sure they were square. Could not notch them so they are basically 2x2. Using tightbond III wood glue and a screw to secure the coroners.

trailer 008.JPG


I did not put a pic in of the trunk space with power to charge phone, tablet, and camera.

trailer 002.JPG


Another pic that was forgotten. The sleeping 3rd panel 38"x12" 1/2plywood. Attached with a 38" piano hinge so it folds down.
trailer 004.JPG


trailer 005.JPG



I put a compression type weather stripping to keep the rain out. This got put on in a thunderstorm going to Tom's M&G.
trailer 003.JPG


view of the length of sleeping area.
trailer 006.JPG


The straps hold the sleeping platform up when fully erected.

trailer 007.JPG


When I started this I had 8" wheels on and decided to put on 12"wheels on. Since I wanted new tires for the Alaska trip I got the bigger ones.
That screwed up the dimensions for the legs, packing it up, and how to get in the trailer.

The height of the trailer to the bike.

trailer 009.JPG
 
It is a shame about the height change Wes but for long distance you are much better off with 12inch wheels ( less rotations for the bearings means less heat and lesser chance of failure) :yes:
 
tires also ... nice work wes ...good planing or did you wing it like i do things ...results are fantastic in all aspects ...very nice looks like bike will handle it to me ...best test this thing good ... and slowly work up up to speed with many test runs ..lot of slow work first id say ....
 
I did ride about 1,000miles to M&G at Tom's with just the cargo, first box completed. I was able to do 80mph with stuff packed and had no problem.
I used I-71 to get it to and from the seamstress along with a township road. The twp rd had a million deep potholes. It was experience for the roads up north. I-71 was a breeze up to 80mph and did not have any problem.

Now I am to tear the bike down and put some new shock springs in the rear.

Thank You for all the kind words.
 
[url=https://classicgoldwings.com/forum/viewtopic.php?p=143508#p143508:hamub6r8 said:
kerryb » Tue Mar 17, 2015 10:39 am[/url]":hamub6r8]
That's a very nice rig. You do good work!
Best of luck on your trip north.
+1 :good: :moped: :yes:
 
Very Nice , I have thought about building something like that for years , I built a Teardrop camper , and we are members of a Teardrop club. and I have met a couple of Motor Cycle guys who built real small Teardrops . i always think about how hard would it be to stop it , and if you run into hard Rain and High Winds ??? i might try it with my Trike . . have you ever had it weighed ?? :popcorn:
 
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