M101a2 Overland Trailer Build

Over the summer (and likely next summer) I am going to be working on turning the M101a2 surplus trailer I purchased into an Overlanding/camping/utility trailer.

I'd like to end up with a trailer that has a RTT, water storage, and a pull-out kitchen.

I am hoping this can be a family project to teach my kids some basic skills and for me to get back into welding.

All journeys start with a single step and all good threads start with some pics.







April 15th Update:

I started working on coating the bed of the trailer. As this is a budget build, I went with a DIY solution rather than LineX.

Started the prep by removing the old tie down hooks, reflectors, and tailgate. The tailgate was a pain in the a** because the cotter pins were not coming out. Since this is a military trailer, I used a military solution and got a bigger hammer. A couple of whacks on the hinge pins sheared off the cotter pins and the hinge pins came right out.



I started to spray the tailgate with Rust-Oleum rust reformer but the rain quickly ended that.



With prep complete and the sun going down I packed it in for the night.



I woke up early this morning to get started as we have one of our family easter celebrations today.

I opened the gallon can of Duplicolor Bed Armor, the kevlar particulate was heavily clumped and I resorted to using a power mixer on my drill. After about 5 min of mixing, it was well distributed.



I don't have any pictures of the process, as my gloved hands were covered in bed liner, but I can tell you that the roller that comes with the kit sucks! The small screw that keeps the handle and roller attached quickly broke and made using the roller vert difficult. I resorted to brushing on the bed liner and using the roller to evenly distribute the kevlar media.

I don't yet know if I regret not going with the Rust-Oleum brand bed liner but time will tell.

Here is the first coat, I will likely try using some of the same brand bed liner in aerosol form to reduce the texture.







The obligitory Taco pic:


Did a little more painting this weekend.

I painted the center panels a gray and used Rustoleum bed liner for the front, top and fenders. Now I just have a little overspray to clean up. I wanted to get this done in preparation for a tonneau cover I ordered last week.









Updates have been sparse lately as I have been busy working and not posting. We had a Memorial Day camping trip coming up and I really wanted to have the trailer ready to take and have it be useful as something more than a cargo hauler.

The first thing I knew I needed was power because I wanted to add a water tank and pump. I needed somewhere to put it so I began looking for a large tongue box that could hold a 10 gallon water tank batteries and power controls. I came up with this for $100 off a Facebook Marketplace ad:



After trying to install it I realized the I would have to relocate the hand brakes and that the tongue weight would quickly get out of hand. So I scrapped that idea and added a Harbor Freight 3 cu ft tongue box. I bolted it directly to the frame but went through 2 taps trying to thread the holes. :-( At the same time I added an adjustable wheeled jack.



Next was adding a trailer hitch to carry bikes. After bolting it to the rear cross frame member, I quickly realized that it was not stiff enough to hold the bike carrier without developing stress cracks. I re-enforced the back "bumper" by partially boxing it and welding the hitch to it.





Next, I was on to wiring the tongue box for power. I used a cheap deep cycle battery from the local Fleet Farm with a 175 minute RC, I don't know what that equates to in AH.

I also added a fuse block,

$29 BEP 701 Battery Disconnect Switch

main battery shut-off and waterproof switch for the water pump.









For water, I added a

$159 Barker Manufacturing Company 11916 20 Gal. Water Tank Kit , White

20-gallon water tank from Amazon with a

$28 Seaflo 12V DC 1.2 GPM 35 PSI 21-Series Diaphragm Water Pressure Pump for Caravan/RV/Boat/Marine

Seaflo 1.2GPM pump and

$18 Camco TastePURE RV Water Filter - New Advanced 6-Step Patent-Protected Filtration - Camping Essentials for Fresh Drinking Water - RV Inline Water Filter w/Flexible Hose Protector, Made in USA (40043)

Camco water filter.

I temporarily mounted this all to a board in the trailer until I can weld up a mounting system for under the trailer.







Lastly, I added some steel cable and clips to hold the tailgate level for use as a workspace. A 20lb propane tank is held in place with a ratchet strap until I get a proper mount.

 

sub'd

 

OP Updated.

Next steps:

Finish bed liner

Find a tonneau cover for a (82-96) LWB Ford F250

Build a pullout slider for a camping kitchen with sink, area for stove and storage.

Decide on what welder to buy for building the rack for a RTT. I haven't welded in a decade so I'll have to practice a little before going to town on the trailer.

Oh, and paint the exterior at some point.

 

Trailer builds are always cool, excited to see where yours goes! I have a little scratch built trailer that I have some similar goals for. Its slow going but eventually it'll be something

 

If you are interested in keeping the original military trailer plug connector mount the plug receptacle on the pintle hitch mount. That way you can easily use the trailer on any vehicle. hitch ball mount.

 

Ohhhh, I like that! The previous owner spliced in a 4pin to the original wiring, I was considering pulling it all out and running new wire and LED lights.

Where did you get the harness? I have seen a few on ebay for $75 but nothing like what you have.

 

I got my receptacle parts from Saturn Surplus. Also I attached a couple of wiring diagrams.

 

Looking great bud, having the hardest time finding one for a good price around me. Put me down for jealous

 

Thanks, I was on Craigslist 3 times a week for 6 months before I found a decent one. I would have preferred an M416 but they were either overpriced or in terrible shape.

 

Op Updated

 

After ordering a tonneau cover that didn't fit (for a Dodge Ram) I found one that worked.

$380 RealTruck TruXedo TruXport Soft Roll Up Truck Bed Tonneau Cover | 238601 | Fits 1973 - 1998 Ford F-150/250/250HD/350 8' Bed (96") , Black

TruXedo 238601 TruXport Soft Roll-Up Dual Latch Tonneau Cover





I am happy with the fit and finish. Now, on to finding a tongue box suitable for batteries and power management.

Anyone now of a good place to look for a water tank I can mount under the trailer?

 

OP Updated.

 

Subbed....my adventure starts.

 

How much does one of these weigh?

 

Around 1300. I think with some work you can get them down to a little over 1000. Max Payload is 2500 highway and 1500 Offroad. So it works as a motocross hauler aswell.