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  #1  
Old 05-22-2012
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Safari Pacific XT1 - Expedition Trailer (Photos)

Restarting the thread since most of my photos have gone from the other thread.

I've decided to build myself an off-road trailer. Mostly to move all of my gear from both of my vehicles to one tow-able package. This way I don't need to swap things back and forth. And partly to build something cool again. More to come.



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  #2  
Old 05-22-2012
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The base chassis is 2 x 4 x 0.125 rectangle tubing. I went with 4 inches tall for added strength.




Old Man Emu Dakar leaf springs from Sierra Expeditions along with hardware and led tail lights.




I start by basic assembly of the suspension and axle. Then check for placement.






After I find the axle placement and distances for tire clearance I make kick-outs for carrying fuel cans.

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Safari Pacific XT1 - Expedition Trailer (Photos)-001.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-002.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-003.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-004.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-005.jpg  

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  #3  
Old 05-22-2012
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Once all sections are cut and tacked into place I finish welding.




Then I move onto building the upper box. Since I didn't want to have the added expense of a one off custom sheet metal box I decided to make a frame to adhere panels too.




Off the main box I run additional tubing to connect to the kick-outs for added strength.






Trying to determine placement of the truck oval led lights. I'm thinking I need to find something else.

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Safari Pacific XT1 - Expedition Trailer (Photos)-006.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-007.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-008.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-009.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-010.jpg  

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  #4  
Old 05-22-2012
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Demo of what I'm thinking. Room on the kick-outs for a 5 gallon fuel/water can or a 20 lb propane tank.




Back to suspension. I had new parts cut out to get the trailers axle where it needs to be. High wise that is.




Ruff setup to check if axle is square with chassis.






Once all aligned I weld up the parts and take the trailer outside to check hight.

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Safari Pacific XT1 - Expedition Trailer (Photos)-011.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-012.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-013.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-014.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-015.jpg  

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  #5  
Old 05-22-2012
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Back inside I swap tires with the Ranger, since they are 32x10.5 tires. I wanted to check clearances and assemble the remainder of the trailer with larger tires.




I also build the tow point similar to how I build Jim's hard side pop-up trailer.




I then toss on the tent mostly for the hell of it.




Next I weld in the floor cross supports, with one beam stronger to attach shock tabs.




Time for skinning.

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Safari Pacific XT1 - Expedition Trailer (Photos)-016.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-017.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-018.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-019.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-020.jpg  

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  #6  
Old 05-22-2012
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I start with the floor section and the front.




Then move onto the sides. I toss on a couple cans just because it makes for a cooler photo.




Once the main body is welded on I start on building the lid.




Then I move onto adding the skin to the lid.




I take off the tires so I can finish up welding where the tires blocked.

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Safari Pacific XT1 - Expedition Trailer (Photos)-021.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-022.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-023.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-024.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-025.jpg  

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  #7  
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I like to over build. Good example is where the chassis tubes are split for the tongue.




With the trailer on its side I weld up all the small bits I couldn't get to from the top.




Before I flip back over and set up on jack stands I use the pallet scale to weigh in. So far what you see is 390 lbs. Not too bad.

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Safari Pacific XT1 - Expedition Trailer (Photos)-026.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-027.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-028.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-029.jpg  
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  #8  
Old 05-22-2012
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In between doing the metal work I decided to start figuring out what color to paint the trailer. At the paint store I picked a color I though would look good. Turned out the name of the color was "money." The color swatch looked good at the store, though once back at the shop the color was brighter than I wanted.



So I mixed small portions with black and brown to get something I like. I call the new color "dirty money"

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  #9  
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I modified the spring plate to add a bit more strength. Also painted them and the other suspension parts.




Welded on the trailer jack attachment point.




Then began to spray primer.






Next I sprayed on the green. It looks brighter in the photos, though is a more of a gray green in person. Might be the lighting.

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Safari Pacific XT1 - Expedition Trailer (Photos)-032.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-033.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-034.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-035.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-036.jpg  

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  #10  
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I painted the everything the green color since I didn't want to mess around with masking the chassis off over welds.




After drying a for a couple days I attach the hinges lid.




On the other side I attach over center latches. They have tabs that stick out to lock with a padlock.






Next I build the rear door.

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Safari Pacific XT1 - Expedition Trailer (Photos)-037.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-038.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-039.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-040.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-041.jpg  

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  #11  
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I use clamps to hold the door in place where I can mark where the door hinges will bolt to.




I drill the holes and bolt everything together.







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Safari Pacific XT1 - Expedition Trailer (Photos)-042.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-043.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-044.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-045.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-046.jpg  

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  #12  
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Welded on some shock mounts then finished painting underneath and inside the box.






The latch arrived today for the rear door. So now I can finish that up.

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Safari Pacific XT1 - Expedition Trailer (Photos)-047.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-048.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-049.jpg  
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  #13  
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After the paint dried I attached the springs and axle.




Then set it down on some wheels and the jack.




Next I plasma cut a hole for the latch on the rear door.





I attach the door back on the trailer to figure out how to add a catch.




I had an old cut out from another project that worked perfectly. 3/8 inch plate.

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Safari Pacific XT1 - Expedition Trailer (Photos)-050.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-051.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-052.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-053.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-054.jpg  

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  #14  
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I added some carriage bolts to act as an adjustable stop for the door.




Rear door ready for paint now.




I tossed some gear on the trailer so I have an idea on how to lay everything out and what brackets I'll need.



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Safari Pacific XT1 - Expedition Trailer (Photos)-055.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-056.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-057.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-058.jpg  
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  #15  
Old 05-22-2012
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These are the led tail lights I decided to go with. The trucker oval style doesn't work well with my design of the trailer.





I installed a standard electrical trailer j-box on the tongue. Now its to assembly and wiring.

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Safari Pacific XT1 - Expedition Trailer (Photos)-059.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-060.jpg  
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  #16  
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Next I primer the lid and rear door.






Then paint. It takes a few days to primer and paint since I had to wait for each side to dry.




Then I paint the hinges.




I use some off the shelf truck bed liner to coat the underside of the tent.

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Safari Pacific XT1 - Expedition Trailer (Photos)-061.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-062.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-063.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-064.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-065.jpg  

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  #17  
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During painting the lid I touch up a few spots like the rear door catch.




A couple days later I coat the other side of the tent's underside.




Then is on to final assembly.





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Safari Pacific XT1 - Expedition Trailer (Photos)-066.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-067.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-068.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-069.jpg   Safari Pacific XT1 - Expedition Trailer (Photos)-070.jpg  

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  #18  
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  #19  
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The last photos posted are from January 10th, 2012. On the 13th my dad passed away and the project was put on hold. Currently the trailer is in a friends garage in Mesa, AZ as I had to vacate the shop. I'm hoping this summer I will be able to bring the trailer out to my new place in Temecula, CA and finish it. There's really not much left. Ironically I'll have to trailer the trailer since there is no plate, lights or wheels. More updates to come once I get rolling on the project again.
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  #20  
Old 05-22-2012
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That is one sweet trailer. Good work all around.
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  #21  
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Looks sweet! I want to see it when it comes here.
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  #22  
Old 05-28-2012
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Quote:
Originally Posted by Lord Of War View Post
That is one sweet trailer. Good work all around.
Thanks


Quote:
Originally Posted by 98liftedranger View Post
Looks sweet! I want to see it when it comes here.
Thanks. Sure, I'll post up once its in Temecula.
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  #23  
Old 06-28-2012
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I towed my trailer back with me from AZ yesterday. The trailer towed awesome and I did a small test run down a power line road. Most of the trip I forgot I was even towing anything. Now its to getting it finished up, now that I'll have it near by. Thanks to Dave Druck for helping with a Lock and Roll so I could get the trailer towed here.





Also, I may be selling this once I get it finished. I still need to add up what I've put into it, though it'll be around $3000 for the trailer alone I'm guessing.
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Looks good!
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Old 06-28-2012
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Looks awesome! Love the matching paint.
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