Family Overland Trailer Build - A-Aron

[A-Aron]

 

[A-Aron]

Stage 2 (stage 1 was design and planning)
-Began trailer build Feb 2018.. Main trailer frame and tongue is 2"x3" 3/16" wall rectangular steel. The remaining of the trailer frame is 2x2" 1/8" Square steel. Welded and coated with self etching primer for rust protection.

 

[A-Aron]

Although Plywood wasn't my ideal choice for an Overland trailer.. its proven strength and ease to work with and relative versatility won out over much more expensive options. It allowed my design to be flexible to change as the build came together.. all joints are glued, screwed with pocket screws, and stapled with a crown stapler to ensure that everything stayed assembled after many many miles of off-road and washboard torture.
The space between the wheel wells holds a 40 gallon water tank and sits flush with the bottom of the frame. Placement was to ensure the load was carried by the suspension and to keep the center of gravity as low as possible.

 

[A-Aron]

There is 10" of space below the bed that allows for a 50"x 20" drawer. The airlines, electrical lines, 3 gallon air tank and additional storage. The area above is 60"x80" to fit a queen mattress for my wife and I. Independent airbag controls allow for leveling the trailer with ease at camp. 3/16 air lines, fill valves, and slow dump valves are all controlled in the main control panel from the exterior as well as a centralized electrical control panel for 12v and 120v areas of the trailer.

 

[A-Aron]

Exterior is sheeted with aircraft grade aluminum that I used a few flush cut router bits on. Roof has a layer of tyvek between the sheeting and plywood. Bottom 12 inches of the sides and underside of the trailer are coated with bedliner.

 

[A-Aron]

Suspension consists of 2 x 2500lb Airbag springs and Rancho rs9000xl adjustable shocks (pictures show the old Monroe shocks I installed originally) With 2" Energy Suspension bump stops. I welded 7000lb trailer axle spindles that were machined for a precise fit into sch80 pipe with 12" electric trailer brakes. I used 1/2" grade 8 bolts to attach the trailing arms to the heavy 3x2 3/16 cross member on the underside of the trailer with energy suspension polyurethane bushings.

 

[A-Aron]

The front and rear of the trailer got red aluminum diamond plate from www.cutsmetal.net and everything was trimmed out with taped seams, butyl tape, and 3/4"x 1/8" black aluminum angle. Then I added a 3 speed vent fan for hot summer nights.

 

[A-Aron]

Cabinetry in sleeping area and kitchen was all done in 1/2 plywood coated with Shelac to keep the natural charm. It is very strong, light, and provides more storage than we know what to do with. Cut a small pass through into the kitchen that has proven extremely handy and is probably one of my wife's favorite features.. Second only to not sleeping on the ground.. I covered the area at the feet and headboard of the bed with outdoor grade carpet and cut a small storage box into the headboard to utilize space that would otherwise be wasted behind the kitchen sink.

 

[A-Aron]

The kitchen.. Crown jewel of the build! Holds a 60L 12v/120v fridge, sink, Camp Chef Mountaineer 40k btu stove. Drawers for dishes/utinsils, tons of space for dry goods. Bluetooth stereo, under cabinet lighting, storage for griddle, frying pan, cutting board, pots, etc. I used softclose 100lb ball bearing drawer slides that stay closed without a latch due to the soft close mechanism. the fridge is on 3/4" 500lb full extension ball bearing slides. Stove slides out on slides then folds down with an adjustable leg for support so it can be positioned level regardless of the terrain.

 

[A-Aron]

Plumbing...
Onboard water pump is a seaflow 3gpm pump and hot water is provided by Eccotemp 7l on-demand propane water heater that is inside it's own cabinet accessible from the exterior and vented through the roof. It can be isolated and drained during cold weather to prevent pipe burst and provides nice hot water for cooking, dishes, and bathing. This is very handy considering we have 3 small children that love dirt and rocks more than anything else in this great world.
Water lines are plumbed in 1/2 color coded PEX and the propane is plumbed throughout with propane specific quick connect fittings that provide individual shut-off at each connection. Makes it nice to hookup stove, Mr. Buddy heater, Propane firepit.. etc without ever moving the tank. I keep a 5' and 12' propane extension hose that can be joined to move the firepit or stove anywhere around the trailer.

 

[A-Aron]

Electrical: Powered by solar and a 100ah AGM battery everything is ran to the main panel that allows the on-board air compressor, fridge, and airbag controls to be operated while all other systems are powered off with the master switch. 12v and 120v systems are completely independent. I have a 30amp 12v power supply that can run the entire trailer if connected to shore power and also provide additional charge to the battery. I use it mostly at home when the trailer is in the garage.. as we only have dry camped thus far. Power is also ran to the RTT which has a led strip for lighting and 12v plug with usb charging. This allows 12v accessories like travel blankets to be used in cold weather or charging of devices.

 

[A-Aron]

Finished her up with a roof rack, ladder, Tuff Stuff Elite Overland RTT, tongue storage, and some rock deflection guards I made out of leftover red diamond plate aluminum. Currently is running on 32" Wild country XTX tires on Toyota 17" Stock wheels to match my rig. Ended up with 22" of clearance on the bump stops to the frame. She pulls great, has very manageable tongue weight and weighs in about 3000lbs when fully loaded with 40 gallons of water, propane, clothes, food, bedding etc.. for a week. As my Sequoia is rated at 6500lbs towing capacity.. it is a good pair that is very manageable.

 

[A-Aron]

Recently added a crib sized fold up bunk bed above our feet in the sleeping area for our youngest that folds up against the front of the trailer inside and provides a 6" shelf above our feet when folded up .. for now.. the other 2 children sleep in the RTT soundly though even the worst of wind and rain. I highly recommend the Tuff Stuff Elite RTT with annex and floor. https://tuffstuff4x4.com/products/elite-overland-roof-top-tent-and-annex-room/ It has proven true to the name in 60+ mph winds in Death Valley and many rainy cold nights with happy dry children in the morning. The attachable annex is HUGE and is a great place to run a Mr. Buddy heater to take the edge of on really cold nights.

 

[Knitron]

Sweet looking trailer. Very unique compared to most off road trailers. Large kitchen and very roomy overall.

 

[Haterade_H3]

Amazing build! Very nice storage ideas and overall great craftsmanship [emoji106]

 

[Prerunner1982]

Well done. I like the larger entry door, quite different.
Thanks for sharing.

 

[Daryl 32]

WELL DONE !

 

[A-Aron]

Well done. I like the larger entry door, quite different.
Thanks for sharing.

Thanks, the larger door on the passenger side has a small "entry way" just enough room to change your pants without doing it laying in bed, and to access storage right there. Also makes a nice place to put shoes and hang your coat without getting them on the bed. Trailer box and frame width is 79.75" Wheels stick out to about 82-83"

 

[John Brown]

WOW!!!! Amazing building

 

[John Brown]

How did you determine where to weld the mounts for the wheels and suspension?