Off-Road Hard Sided Popup Trailer - Page 3 - 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.

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  #51  
Old 05-28-2012
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Quote:
Originally Posted by 98liftedranger View Post
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.
I still don't think so. He way more of a nerd than I am....haha.

I don't have any special deals. I use Industrial Metal Supply and get there regular discount when you order large amounts.


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Originally Posted by 06RangerXLT View Post
dam your a little guy.

i should just get ya to build my truck, im sure it would be perfect.
I'm 5' 7" and 160 lbs (now) I'd say I'm average, just every else are giants...haha

Thanks. Yeah, I'm open to building anything for anyone. Just costs that money stuff.


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You do great work dude
Good job on the build.
Thanks!
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  #52  
Old 05-28-2012
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Next I pull off the body from the frame.




Then take it outside to sand blast.




The tires are covered and chassis is cleaned with thinner.




The whole chassis gets a layer of heavy duty paint. (Customer requested paint over powder coat)



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

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  #53  
Old 05-28-2012
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Once dry I roll it back inside and place strips of neoprene foam on the edges. This is to keep the aluminum from rubbing against the steel chassis.




Suspension components are installed. Air line is connected and electrical wires are run.





Attached Thumbnails
Off-Road Hard Sided Popup Trailer-046.jpg   Off-Road Hard Sided Popup Trailer-006.jpg   Off-Road Hard Sided Popup Trailer-007.jpg   Off-Road Hard Sided Popup Trailer-008.jpg  
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  #54  
Old 05-28-2012
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pure sex. love that thing. a slightly smaller version that can fit a motorcycle, and a canoe on top would be perfect for me :)
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  #55  
Old 05-28-2012
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The body skeleton is reattached and floor set in place. Then its onto finishing the skin.




The upper portion gets skins cut to fit.




More cutting sheets of aluminum to fit then attaching using 3M's VHB tape.





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Off-Road Hard Sided Popup Trailer-046.jpg   Off-Road Hard Sided Popup Trailer-047.jpg   Off-Road Hard Sided Popup Trailer-048.jpg   Off-Road Hard Sided Popup Trailer-049.jpg   Off-Road Hard Sided Popup Trailer-050.jpg  

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  #56  
Old 05-28-2012
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Between installing the skin I start working on the doors and latch.




The two doors allow access when the lid is up or down.




Inside view of latch and door jam.




Doors get skinned once latch, door jam and seals are in place.



Attached Thumbnails
Off-Road Hard Sided Popup Trailer-051.jpg   Off-Road Hard Sided Popup Trailer-052.jpg   Off-Road Hard Sided Popup Trailer-053.jpg   Off-Road Hard Sided Popup Trailer-054.jpg   Off-Road Hard Sided Popup Trailer-055.jpg  

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  #57  
Old 05-28-2012
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What are the plans for paint on it? Won't the inside get really really hot when its in the sun?
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  #58  
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With the main exterior panels completed I move on to the lift system. I design some brackets for the electric lift rams to attach to. They are cut out via a plasma cam then painted. Each corner of the trailer body gets a pair.




The flat spot on top clears the body of the rams. The inner curve is the cut exactly to fit around the lower body's top edge. These are also on the upper lid/roof section.






Long sections of aluminum are bent to cap off the step on the lower body exterior.



Attached Thumbnails
Off-Road Hard Sided Popup Trailer-056.jpg   Off-Road Hard Sided Popup Trailer-057.jpg   Off-Road Hard Sided Popup Trailer-058.jpg   Off-Road Hard Sided Popup Trailer-059.jpg   Off-Road Hard Sided Popup Trailer-060.jpg  

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  #59  
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The roof section is then set on top before the exterior skin is attached. This is to align the electric lifts and have access to adjust them.






Electric rams are attached and given a first test. It was late when we finally got to test them. Thankfully they worked the very first time exactly how the should of. We did have to adjust them a 1/4 inch lower. A testament to designing everything on a computer first.






Here's a video of the first test. The battery we used was not fully charged, so took a bit to open and close.

www.youtube.com/watch?v=qX_9uropPuM&list=UUFHpv_6iLsf64dSqldmzGQA
Attached Thumbnails
Off-Road Hard Sided Popup Trailer-061.jpg   Off-Road Hard Sided Popup Trailer-062.jpg   Off-Road Hard Sided Popup Trailer-065.jpg   Off-Road Hard Sided Popup Trailer-064.jpg  
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  #60  
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With the lifts working properly we finished skinning the exterior and installed the windows.






The door was trimmed with 2 inch wide aluminum strips for an outside edge for the weather stripping.




The split between the doors has weather stripping as well.




Final adjustments on the latch catch are made.

Attached Thumbnails
Off-Road Hard Sided Popup Trailer-066.jpg   Off-Road Hard Sided Popup Trailer-067.jpg   Off-Road Hard Sided Popup Trailer-068.jpg   Off-Road Hard Sided Popup Trailer-069.jpg   Off-Road Hard Sided Popup Trailer-070.jpg  

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  #61  
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All the edges then got trim. Attached with 3M VHB tape. This took a few days.

The final results were awesome.










One thing that wasn't finished on time was the spare tire carrier.




We finished right on the deadline. So we decided to have a couple beers. The next morning Jim had to begin his long drive back home.

Attached Thumbnails
Off-Road Hard Sided Popup Trailer-071.jpg   Off-Road Hard Sided Popup Trailer-072.jpg   Off-Road Hard Sided Popup Trailer-073.jpg   Off-Road Hard Sided Popup Trailer-074.jpg   Off-Road Hard Sided Popup Trailer-075.jpg  

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  #62  
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The next morning I followed Jim out of town. We hit a small trail to do quick testing and snap a few photos.









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Off-Road Hard Sided Popup Trailer-test01.jpg   Off-Road Hard Sided Popup Trailer-test02.jpg   Off-Road Hard Sided Popup Trailer-test03.jpg   Off-Road Hard Sided Popup Trailer-test04.jpg   Off-Road Hard Sided Popup Trailer-test05.jpg  

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  #63  
Old 05-28-2012
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Trailer looks a bit dirty since we forgot to wipe all our hand prints off before taking photos. After working 16 hour days strait for over a month, I wasn't all there mentally. This project is definitely one of the coolest things I've done and would like to build myself something similar one day.







From here Jim started building the interior out. I don't have any photos right now, though I'll ask him if he can send me some. The aluminum sheeting got a layer of high-density polyethylene (HDPE). Then a layer of polystyrene for insulation.
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Off-Road Hard Sided Popup Trailer-test06.jpg   Off-Road Hard Sided Popup Trailer-test07.jpg   Off-Road Hard Sided Popup Trailer-test08.jpg  
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  #64  
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Originally Posted by 98liftedranger View Post
What are the plans for paint on it? Won't the inside get really really hot when its in the sun?
The walls got a layer of HDPE and polystyrene foam for insulation. Jim, the owner, eventually painted the exterior gray. I personally liked it better with the aluminum showing. Looked more classic.
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  #65  
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i would have put the roll out shade on the under side of those top windows. would allow more light, better coverage and probably easier to reach.

other then that, i like it.
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  #66  
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Originally Posted by 06RangerXLT View Post
i would have put the roll out shade on the under side of those top windows. would allow more light, better coverage and probably easier to reach.

other then that, i like it.
We talked about placing it there but overall the customer wanted it on top. So when he had the top lowered (stealth camping) he could still have the awning out. I should mention, when the top is lowered you can still sit with plenty of room above your head.
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  #67  
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The trailer and the truck are badass!!
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  #68  
Old 05-29-2012
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Pretty sweet and I am interested in seeing interior shots.
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  #69  
Old 05-29-2012
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Travis, you did it again. Your work is top notch my friend.
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  #70  
Old 05-29-2012
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Looks excellent! I can't help but think of how hot that would get though.
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  #71  
Old 05-29-2012
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Thanks everyone!

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Looks excellent! I can't help but think of how hot that would get though.
Thanks! The final trailer has insulation in the walls, a roof van/vent and an AC unit.
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