Off-Road Hard Sided Popup Trailer - Page 2 - Ranger-Forums - The Ultimate Ford Ranger Resource


Fabrication & Tool Tech Need assistance with or ideas for custom metal fabrication? Want to show off your fabrication abilities or custom modifications? This is the sub-forum for you.

Reply
 
LinkBack Thread Tools Search this Thread
  #26  
Old 05-11-2012
SteelDirigible's Avatar
Member
iTrader: (4)
 
Join Date: May 2010
Location: Lexington, KY
Posts: 3,666
plus it looks badass. haha.
Reply With Quote
  #27  
Old 05-11-2012
Member
 
Join Date: Nov 2011
Location: Pittsburgh, Pa.
Posts: 23
Wow, 1,600lbs empty, that is pretty lite. keep up the good work man.
Reply With Quote
  #28  
Old 05-12-2012
Scrambler82's Avatar
Old Guy Userů ltr
iTrader: (12)
 
Join Date: Jul 2009
Location: SoCal
Posts: 6,777
Nice work.
Looks impressive should take a beating.
Is there an interior plan ?
Reply With Quote
  #29  
Old 05-12-2012
FULLSCALE's Avatar
Level III Supporter

iTrader: (12)
 
Join Date: Mar 2009
Location: Clinton, Ontario
Posts: 8,181
Can't wait to see this thing done!
Reply With Quote
  #30  
Old 05-12-2012
98liftedranger's Avatar
RF Veteran
iTrader: (5)
 
Join Date: Aug 2008
Location: California
Posts: 12,538
I would love to see this when its done. Does the guy live in Riverside County? Or is that just where your working on it (Temecula)?
Reply With Quote
  #31  
Old 05-12-2012
06RangerXLT's Avatar
Member
iTrader: (2)
 
Join Date: Feb 2011
Location: Halton Hills, Ont
Posts: 1,685
id love a smaller version of this for me... giving me ideas...
Reply With Quote
  #32  
Old 05-12-2012
Lord Of War's Avatar
Member
iTrader: (2)
 
Join Date: Jan 2006
Location: Thornton, Colorado
Posts: 4,599
When you can I would like to see a picture of the top lifted.

This is a great build!
Reply With Quote
  #33  
Old 05-22-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
Quote:
Originally Posted by MidnightRebel07 View Post
Wow, 1,600lbs empty, that is pretty lite. keep up the good work man.
The plan was to keep it as light as possible. Once it rolled out it only had 60 lbs of tongue weight. Needless to say, we tipped it a few times while inside working. Messes with your head when the world starts moving under you...haha

Quote:
Originally Posted by Scrambler82 View Post
Nice work.
Looks impressive should take a beating.
Is there an interior plan ?
Thanks! Yeah, the owner will be finishing that tough. I was only contracted to build the chassis and body.

Quote:
Originally Posted by 98liftedranger View Post
I would love to see this when its done. Does the guy live in Riverside County? Or is that just where your working on it (Temecula)?
It looks awesome. I haven't seen it with interior yet though. The owner lives on the east coast. I built this at my shop in AZ back in 2010.

Quote:
Originally Posted by 06RangerXLT View Post
id love a smaller version of this for me... giving me ideas...
I thought about building me one on the smaller scale. Its very expensive to build even on a small scale.

Quote:
Originally Posted by Lord Of War View Post
When you can I would like to see a picture of the top lifted.

This is a great build!
Thanks! I have a few of the finished trailer on a trail and with the top lifted. Those photos are coming.
Reply With Quote
  #34  
Old 05-22-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
Another angle of the windows.




The door turned out to be tricky. Lots of weird angles.






A better shot of the lower rear section

Attached Thumbnails
Off-Road Hard Sided Popup Trailer-022.jpg   Off-Road Hard Sided Popup Trailer-024.jpg   Off-Road Hard Sided Popup Trailer-025.jpg   Off-Road Hard Sided Popup Trailer-026.jpg  
Reply With Quote
  #35  
Old 05-22-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
On to the upper roof section. Following the same bending technique we form the outer roof supports and weld in place.




Supports and lower tubing welded on.




Cross bar and window tubing are welded on then set on the main body.




The other side is then built. Then both sides are connected together.

Attached Thumbnails
Off-Road Hard Sided Popup Trailer-027.jpg   Off-Road Hard Sided Popup Trailer-028.jpg   Off-Road Hard Sided Popup Trailer-029.jpg   Off-Road Hard Sided Popup Trailer-030.jpg  
Reply With Quote
  #36  
Old 05-22-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
After all the major parts are welded we hook the trailer to the truck. We drive over to a flat part of the yard to see how it looks. Then take measurements to for the air bag setup for proper ride height.





Attached Thumbnails
Off-Road Hard Sided Popup Trailer-031.jpg   Off-Road Hard Sided Popup Trailer-032.jpg   Off-Road Hard Sided Popup Trailer-033.jpg  
Reply With Quote
  #37  
Old 05-22-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
The upper roof section is pulled off and set on the floor. Its skinning time.




We start at the rear. The end sections have to be pre-bent by hand to fit the curve. We attached the skin with 3M's VHB tape. This was a very tedious process and no room for error. The VHB tape is super strong and once it touches, there's no pulling it off. The VHB tape was used in place of rivets. Rivets would take a long time to install, plus are another place to leak.






The rest of the sheets were laid over each other. This made all the seams face rearward. So during movement water and dust will roll over the seams and keep going.



Attached Thumbnails
Off-Road Hard Sided Popup Trailer-034.jpg   Off-Road Hard Sided Popup Trailer-035.jpg   Off-Road Hard Sided Popup Trailer-036.jpg   Off-Road Hard Sided Popup Trailer-037.jpg   Off-Road Hard Sided Popup Trailer-038.jpg  

Reply With Quote
  #38  
Old 05-22-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
Inside view.



Rear kick-up skin was cut and bent.

Attached Thumbnails
Off-Road Hard Sided Popup Trailer-034.jpg   Off-Road Hard Sided Popup Trailer-035.jpg   Off-Road Hard Sided Popup Trailer-036.jpg   Off-Road Hard Sided Popup Trailer-037.jpg   Off-Road Hard Sided Popup Trailer-038.jpg  

Off-Road Hard Sided Popup Trailer-039.jpg   Off-Road Hard Sided Popup Trailer-040.jpg  
Reply With Quote
  #39  
Old 05-22-2012
morris's Avatar
RF Veteran
iTrader: (5)
 
Join Date: Feb 2008
Location: South Detroit.
Posts: 7,833
Woah, coming along eh?
Reply With Quote
  #40  
Old 05-22-2012
SteelDirigible's Avatar
Member
iTrader: (4)
 
Join Date: May 2010
Location: Lexington, KY
Posts: 3,666
i see the hitch coupler is just bolted into the tube, was that permanent?
Reply With Quote
  #41  
Old 05-22-2012
FULLSCALE's Avatar
Level III Supporter

iTrader: (12)
 
Join Date: Mar 2009
Location: Clinton, Ontario
Posts: 8,181
Awesome work!
Reply With Quote
  #42  
Old 05-22-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
Before getting to far ahead, some steel work needs to be finished. The step is filled in with 3/16inch plate.




The front section is given a 3/16 inch gusset since the base step frame is only 1/8inch thick.




Corner marker lights are given 1/4 inch guards.




As well as the brake lights.




The tongue is given 1/4 inch plate reinforcements where the 2x4 tubing is welded together.

Attached Thumbnails
Off-Road Hard Sided Popup Trailer-041.jpg   Off-Road Hard Sided Popup Trailer-044.jpg   Off-Road Hard Sided Popup Trailer-042.jpg   Off-Road Hard Sided Popup Trailer-043.jpg   Off-Road Hard Sided Popup Trailer-045.jpg  

Reply With Quote
  #43  
Old 05-22-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
On to air bags. I spent a while to figure out the geometry in CAD for the suspension. I wanted to make sure the air bags didn't overextend, compress too much or tear from the axle swinging forward. Then I had a neighboring shop cut the parts out with their PlasmaCam. Upper and lower air bag plates are then fastened to the air bags.




Shock mount/reinforcing brackets are tacked on lower air bag plate.




A 2x4 section of chassis tubing is welded on to attach upper plate of air bag.




Upper shock tabs are welded on to chassis and gussets are welded on upper air bag plate.




After everything is tacked in place air bags and shocks are removed for final welding. The shock used is just temporary. The shocks ordered didn't arrive in time, so we used some cheap ones that were the same length.

Attached Thumbnails
Off-Road Hard Sided Popup Trailer-001.jpg   Off-Road Hard Sided Popup Trailer-002.jpg   Off-Road Hard Sided Popup Trailer-003.jpg   Off-Road Hard Sided Popup Trailer-004.jpg   Off-Road Hard Sided Popup Trailer-005.jpg  

Reply With Quote
  #44  
Old 05-22-2012
98liftedranger's Avatar
RF Veteran
iTrader: (5)
 
Join Date: Aug 2008
Location: California
Posts: 12,538
Looks great!

You look like Mark Zuckerberg though.
Reply With Quote
  #45  
Old 05-25-2012
Member
Thread Starter
 
Join Date: Jul 2008
Location: Temecula, CA
Posts: 115
Quote:
Originally Posted by 98liftedranger View Post
Looks great!
Thanks!

Quote:
Originally Posted by 98liftedranger View Post
You look like Mark Zuckerberg though.
Not so much....

Attached Thumbnails
Off-Road Hard Sided Popup Trailer-006.jpg  
Reply With Quote
  #46  
Old 05-25-2012
98liftedranger's Avatar
RF Veteran
iTrader: (5)
 
Join Date: Aug 2008
Location: California
Posts: 12,538
A little bit. lol But actually he looks like you since your older.

Do you get deals on DOM? What about square? I need about 80 feet for something I am building.
Reply With Quote
  #47  
Old 05-25-2012
06RangerXLT's Avatar
Member
iTrader: (2)
 
Join Date: Feb 2011
Location: Halton Hills, Ont
Posts: 1,685
dam your a little guy.

i should just get ya to build my truck, im sure it would be perfect.
Reply With Quote
  #48  
Old 05-25-2012
PSIJOE's Avatar
Member
 
Join Date: Nov 2011
Location: Sacramento, CA
Posts: 1,311
I will be commenting on this in a while. Just saving it for now.
Reply With Quote
  #49  
Old 05-25-2012
Josh40601's Avatar
Member
 
Join Date: Jun 2011
Location: Kentucky
Posts: 376
dammit! Stop teasing! Post the pics!
Reply With Quote
  #50  
Old 05-26-2012
Jake9488's Avatar
Member
 
Join Date: Jan 2012
Location: California
Posts: 116
You do great work dude
Good job on the build.
Reply With Quote
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
Popup Camper Clay Kann DOHC - 2.3L Duratec / Mazda L Engines 24 08-05-2014 04:33 AM
For Sale: FS: Off Road Utility Trailer (Napa, CA) $825 Melt Interior, Exterior, Electrical, & Misc. 0 08-04-2011 08:55 PM
Double Sided Tape limE Exterior Semi-Tech 8 07-02-2010 02:10 PM
Trailer or bed swap to haul quad? (bigger pic of trailer) Alon General Ford Ranger Discussion 20 12-13-2004 06:17 AM


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -6. The time now is 08:24 AM.


We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.