gwolff's Cargo Trailer Camper Conversion

Hello all! I found this forum thanks to Google and @Shmellmopwho 's cargo trailer build thread. I posted in his thread because I was so excited to find someone who was far along in the same project I just began undertaking. After all the great feedback I decided to post updates but I was basically clogging up Shmellmopwho's thread. So now I am making my own.

I am converting a 5x8' cargo trailer (Interstate Trailer's Loadrunner) to a camper that is off road capable. My Jeep has a tow capacity of 3500 lbs and a max tongue weight of 350lbs. For that reason, the trailer must be lightweight and properly balanced.

Originally, my goal was to build a trailer from the ground up. Once I realized it would be a pain to register it, I thought it would be easier to go with a flat utility trailer. Then I realized I could just get an enclosed trailer for a tiny bit more money and avoid building walls and putting on siding and painting. So, here I am with an enclosed cargo trailer.

Here is a list of what I have accomplished so far. I began this project in early November.

1. Replaced Dexter drop axle with Timbren Axleless Suspension (3500lb with 4 inch lift, model ASR35HDS02)
2. Converted ball coupler to receiver hitch and extended tongue 3ft. Receiver hitch is necessary to function with the Max Coupler articulating hitch.
3. Built fenders/steps to accommodate new tires and add functionality.
4. Reinforced the frame with a lot of additional tubing.
5. Fabricated some brackets for awning and mounted
6. Stripped inside of trailer of all plywood

Now for pictures:

Here's the trailer stock


Installing new suspension



Adding brakes and wheels:


Making Fenders:





New Tongue:


Reinforced Tongue:


Test drive before fenders just because:


Mounted Awning:


This is how the trailer looks today, December 9th, 2017. I am planning to accomplish a lot tomorrow and I will definitely post updates.

Thanks for reading!

 

Very Cool!

 

So awesome dude!! It’s looking great. I’m subbbbbed to the build!

 

Lookin good man

 

Update! Sunday Work Day! I got everything I wanted to get done today:

1. Painted front diamond plate black
2. Painted exposed metal on underside of trailer to protect from corrossion
3. Coated plywood with flex seal to prep for installation as floor
4. Permanently mounted awning with bolts and siliconed the holes
5. Welded up the box for the trailer tongue and put in the expanded metal bottom. It just needs a latch and its ready to go.

Pictures!

Painting the front diamond plate (really takes it to the next level!)



Deploying the awning: (schweet!)


Welded up tongue box:


Seeing how it will look:


So, that's my update for today. Not sure what my plans for this week are but I will slowly but surely wrap up the exterior.

Thanks for reading!

 

@gwolff
Nice work on the trailer!
I'm wondering how you mounted the awning, I have a 6x12 trailer, and want to mount an ARB awning to it.
My best idea so far was to get a couple locking tv wall mounts, so it would be removable when not in use.

 

Looks good!

 

I'm glad you asked! I wanted to mount the awning to the studs in the trailer walls, but I needed to mount it high enough so the door could open. I also couldn't go straight up from the side of the trailer because of the trim in the way. I made some mounting brackets out of flat metal and cut a block of high density polyethylene to act as a spacer so I could clear the trim. Then I used 1/4" bolts with washers and lockwashers and a ton of silicone to seal it. Here's a picture when I used some self tapping panheads to hold the brackets in place temporarily

 

Subbed.....

Always up for a good trailer build.....

 

Great work so far!
Sub’d

 

Lookin good

 

AF

 

It's coming alone nicely. You have some cool ideas. I'm in for the rest of the build.

 

The black paint fixed everything, seriously, the diamond plate looks so much better. The tongue box turned out AWESOME!

 

Hello all!

Unfortunately, not all news is good news. I've spent the last two days trying to come up with a spare tire mount design and nothing I've done thus far works (not just designing, but also fabricating designs that just didnt cut it). I am working on a solution to the problem, and it is all explained in my latest update video on youtube: https://youtu.be/fUvVbotmeSo

The short story of my problem is that the channel I welded inside the wall of my trailer is not sturdy enough to hold the trailer tire mounting bracket. I should have remembered that channel is horrible at resisting torsional stress. I was just thinking about the tire trying to pull outward on the channel and forgot it would also end up twisting it whenever the trailer experiences lateral acceleration. I tried to solve that issue by welding in some strip metal to close the channel into a tube. It significantly improved the problem, but it is still unsatisfactory. I have some plans to solve this which I discuss in the video. I won't be working on the trailer tomorrow. Hopefully I can have it solved after my next work day.

Thanks for reading!

 

I like your solution for keeping that tire mount sturdy. I think that'll work. Trailer is coming along nicely!

 

I actually have two receiver hitches on the rear sides to level the trailer as seen here:



I can't use those to mount the tire since they are mounted so far to the rear unless I got very creative. It would be pretty tough to mount in on the rear, the frame across the rear edge of the trailer is just more channel, couldn't mount directly to it. I am going to try my current plan and see how it goes.

 

I am optimistic! Hopefully Thursday night I can post some good news.

 

An additional piece of channel in the wall and a horizontal piece of tubing did the trick. It's very solid now.

 

Here's a video progress update: https://www.youtube.com/watch?v=YzcIA7yG5B8

The tongue box is painted and ready to be mounted. Just need to paint the tongue first.