No.5 Camper trailer build

[debruiser]

So I'm starting on a lighter weight camper trailer (the slide on was way too heavy. If your not familiar with it, there is a thread here somewhere). Got a ali No5 with a defender length axle and some override disc brakes.

The current plan is to get it cleaned up, painted, freshen up the brakes and get it registered to test out as a box trailer on a camping trip just to get an idea of how it tows etc.

Ultimately I want to modify it (yea all the rivet counters should leave now...) to a camper trailer. maybe a tailgate kitchen, water and diesel tanks, storage, fridgeslide, battery, lights etc. Basic sort of fitout but quick and easy to deploy. Going to have a maggiola airtop on it. I guess I'm looking for ideas other people have used; it's pretty hard to find much online of what people have done... maybe the rivet counters scared them all :p

[Outlaw]

Watching to see what you come up with as I keep changing my mind on how I'm doing my no.5 camper ;)

[numpty]

Check out my build thread for my take on something similar.

[debruiser]

Check out my build thread for my take on something similar.

Ahhh yes, I've been spying on your thread of late. Some cool ideas. I want to keep the original No5 tub though, trying to keep it looking reasonably stock.

[debruiser]

So just adding a couple of photos,
Before: - Obviously the solar panel was just sitting there to charge some batteries...
https://www.aulro.com/afvb/images/imported/2015/01/745.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0005_zps6088f70d.jpg.html)

Tub off, rims repainted (stripped and refitted the tyres), repainted chassis, All new wiring, lights and plug, new master cylinder on the brakes, new brake hoses, regrease the running gear.
https://www.aulro.com/afvb/images/imported/2016/06/226.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0382_zpsbb5e07f8.jpg.html)

Now it's tub time! Got to make the mud guards wider; so the plan is to remove and get wider ones bent up. Also going to chop the inside of the guards down to gain more room inside. It's going to be a fair bit of work but I think it'll pay off in the end.

[Landover]

Nice work. I'm looking at doing the same thing so watching with interest. I just have to find a trailer first though. I was even thinking of using just a No5 chassis and putting my 130 tub on it. It all depends on the condition of the trailer I find.

[debruiser]

Thanks Landover.

After a bit of faffing trying to remove on of the outter guards, i think I'll just extend them. It won't look as good but there has to be a line in the sand. :(

[Landover]

Hard to see how far the wheel stick out in the picture. Is it now the same track as a Defender. I have some pictures at home of a No5 trailer with flares using that rubber stuff they use on some 4wd's, it looked quite good but probably 2 or 3 in wide.

[debruiser]

It's the same track as a defender. So I think I need about 75-100mm of extra on each side... not sure I have to put the tub back on and measure it

[cactus]

have a look on ebay at the moment there is a no5 camper set up you may be able to steal some ideas from. not associated in any way. I have my own no5. also a workshop chassis with a ute body on it waiting to be converted into a wagon rear camper thing. have the sides and roof, just need motivation.


cheers

[debruiser]

Thanks Cactus, some good ideas there to be had. :D

Not much to report today though.... went fishing this morning and the Mrs caught the attached. She was pretty excited to say the least. :)

[Mick_Marsh]

have a look on ebay at the moment there is a no5 camper set up you may be able to steal some ideas from. not associated in any way. I have my own no5. also a workshop chassis with a ute body on it waiting to be converted into a wagon rear camper thing. have the sides and roof, just need motivation.


cheers
This one perhaps?
OFF Road 4x4 Army Camper Trailer in Gracemere, QLD | eBay (http://www.ebay.com.au/itm/Off-road-4X4-Army-Camper-Trailer-/121546859614?pt=LH_DefaultDomain_15&hash=item1c4cc1e45e)
I quite like it.

[debruiser]

Yea I'm pretty sure that is the one he was referring to. I couldn't find many others....

After a bit more playing with the welder I think I have the whole welding Ali with a mig closer to 'under control'. The answer to my woes was MORE POWER! It's not real pretty yet, but definitely getting better.

[debruiser]

Today's max temp was 34 I think... but felt like 41. So today was a bit of a struggle to get much done. However I did get one inner guard removed, took out the little angley bit, flipped it, and tacked back in. I have to take the tub back off the chassis and weld it out, then cut out the other guard and repeat... I'll have to take some pics to post.

Although my welds still look pretty average, at least now they are getting good penetration. I found that a big chunk of plate held under the weld was very helpful to disperse some of the heat.... kept it all looking a lot better.

[debruiser]

So after plenty of chopping, grinding, cutting, welding, headscratching, welding, grinding and of course measuring.....

https://www.aulro.com/afvb/images/imported/2015/08/216.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0003_zpsce697794.jpg.html)

So there she is painted on the inside and underneath. Not the best paint job ever.... but it's a working trailer so it will do and plus this is only stage 1, it'll probably need a whole respray by the time I am finished with it.

https://www.aulro.com/afvb/images/imported/2015/08/217.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0004_zpsa970f36a.jpg.html)

And behind the 90. You can see that I've got it sitting slightly nose down.

https://www.aulro.com/afvb/images/imported/2015/08/218.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0006_zpsf22a020f.jpg.html)

I actually had it mocked up to that height.... I've got a 'drop' hitch that is too low to tow the trailer nicely, so I was testing it 'flipped', see below

https://www.aulro.com/afvb/images/imported/2015/10/806.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0005copy_zps3b004598.jpg.html)

Now the problem is that I can't run that hitch flipped because the spare is fowling; both to hitch it up and if it was to articulate. The way I see it there is 3 options:
1 - Remove the spare when towing the trailer.
2 - get a longer tongue hitch
3 - get a swing away carrier that moves the spare to the right side of the car more.

I'm thinking option 1, then option 3 when I can afford it.
Option 2 to me seems not a good choice; lengthening the tongue will make the car tow less desirably?

What are your thoughts? I'm keen to hear other options/ideas.

[Outlaw]

How about a different tow hitch? Pintle would have sorted it or a treg etc?

[debruiser]

Forgive my ignorance but I'm not up to speed with different hitches... Do you have an example or link to something?

the pintle hitch bit has been removed from the trailer to fit the brake system hitch bit thingo....

[maxthomas]

I'm very interested in how this turns out as I've just acquired a No5 Trailer also. I'm thinking of putting my hannibal rooftop tent on it first then fit it out a bit more later down the track.

[Redback]

So after plenty of chopping, grinding, cutting, welding, headscratching, welding, grinding and of course measuring.....

https://www.aulro.com/afvb/images/imported/2015/08/216.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0003_zpsce697794.jpg.html)

So there she is painted on the inside and underneath. Not the best paint job ever.... but it's a working trailer so it will do and plus this is only stage 1, it'll probably need a whole respray by the time I am finished with it.

https://www.aulro.com/afvb/images/imported/2015/08/217.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0004_zpsa970f36a.jpg.html)

And behind the 90. You can see that I've got it sitting slightly nose down.

https://www.aulro.com/afvb/images/imported/2015/08/218.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0006_zpsf22a020f.jpg.html)

I actually had it mocked up to that height.... I've got a 'drop' hitch that is too low to tow the trailer nicely, so I was testing it 'flipped', see below

https://www.aulro.com/afvb/images/imported/2015/10/806.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0005copy_zps3b004598.jpg.html)

Now the problem is that I can't run that hitch flipped because the spare is fowling; both to hitch it up and if it was to articulate. The way I see it there is 3 options:
1 - Remove the spare when towing the trailer.
2 - get a longer tongue hitch
3 - get a swing away carrier that moves the spare to the right side of the car more.

I'm thinking option 1, then option 3 when I can afford it.
Option 2 to me seems not a good choice; lengthening the tongue will make the car tow less desirably?

What are your thoughts? I'm keen to hear other options/ideas.

All you need to do is get a longer tongue, to get the ball further out from the car to clear the spare, that tongue is too short and not designed to be flipped, because of that angled design.

Work out how far out you need to go to clear the spare, then get the tongue to suit.

This type is the one that is suited to be flipped, it measures 22.7cm from pin hole to ball, with 3500kg rating, the next one longer is 32cm from pin hole to ball, but rated to 2500kg;
https://www.aulro.com/afvb/images/imported/2015/08/219.jpg

Baz.

[simmo]

Hi Redback, I had a similar problem with the wheel fouling the hitch, but I'm using a swing out wheel carrier that has the wheel offset to the right HS and take the weight off the door.
It also carries the wheel a little lower so it doesn't block the back window so much. ( that along with my 42 l sill tank and me make the car lean a little to the right. good looking trailer, its sits high, I love the all alloy tub. is that an ex army trailer chassis ?

[debruiser]

Yea the trailer does sit high.... I have tried a flipped hitch and it leveled it out but couldnt' have the spare on the car.... now i've got a dual spare I dont think i'll be able to use that either.... still working on that one... might extend the drawbar a little and crank it down so levels the trailer and keeps the tow hitch stock on the car.

Yea apparently it's a ex-Navy trailer.

[simmo]

I'll keep my eye out for one, aussie army style is going to be well made for sure. Good ground clearance and not too heavy by the look of them. I agree with you, a small light trailer might be better than a fully loaded roof rack. Plus they look "cute" :wasntme:

[4runnernomore]

Try a ozhitch. https://www.ozhitch.com

I had one fitted to my Cub camper and my box trailer.

Cheers.

[Mick_Marsh]

I'm very interested in how this turns out as I've just acquired a No5 Trailer also. I'm thinking of putting my hannibal rooftop tent on it first then fit it out a bit more later down the track.
Like this? The one for sale on Gumtree.

[debruiser]

Try a ozhitch. https://www.ozhitch.com

I had one fitted to my Cub camper and my box trailer.

Cheers.

Good stuff, but do you know if they do a hydraulic override?

[Redback]

Good stuff, but do you know if they do a hydraulic override?

Yes you just need the override hitch and attach the hydraulic brake unit to it.

I forgot, you can just replace the centre bit of your hitch and slide a new bit in it's place, with any hitch you want, just undo that big nut at the back.

Like this
https://www.aulro.com/afvb/images/imported/2015/08/182.jpg

TREG hitch version
https://www.aulro.com/afvb/images/imported/2015/08/183.jpg

[simmo]

Hi Mick,

the trailer in the add is part of the package, he won't separate. :(.

One of those trailers would make a good project, I'll be looking for a camper trailer next year. It's great if you have your own ali welding capability though.
cheers simmo

[debruiser]

Hi Mick,

the trailer in the add is part of the package, he won't separate. :(.

One of those trailers would make a good project, I'll be looking for a camper trailer next year. It's great if you have your own ali welding capability though.
cheers simmo

Most No5's are steel tub not ali.... I have the odd one out :p

[SG1 Bones]

Maybe it was made out of aluminum because of being a Navy one.

Just a thought.
Nathan.

[debruiser]

Yea I think that's it

Sent from my SM-A300Y using AULRO mobile app

[Mick_Marsh]

The aluminium No5 trailers were RAAF.

[Bearman]

Good work there Nick. Yes it was an ex RAAF trailer. Apparently never been used when I bought it. Good as new, no dents at all.

[ozrob]

Here is a few pictures of my No5 trailer camper trailer build.

https://ozrob.smugmug.com/Army-Camper/Army-Trailer-Camper/i-wBG48ZL/0/M/DSCN0571-M.jpg

https://ozrob.smugmug.com/Army-Camper/Army-Trailer-Camper/i-pzkCtFT/0/M/DSCN0570-M.jpg

Yes the trailer is now my off road camper,
https://ozrob.smugmug.com/Army-Camper/Army-Trailer-Camper/i-xHLRXK4/0/M/DSCN0563-M.jpg

Drifta DSOB Tail gate Kitchen installed

https://ozrob.smugmug.com/Army-Camper/Army-Trailer-Camper/i-4jms8Dw/0/M/DSCN0565-M.jpg

Enough room to mount a Jerry Can for water
https://ozrob.smugmug.com/Army-Camper/Army-Trailer-Camper/i-jJ3LMvs/0/M/DSCN0573-M.jpg

Had to cut the inner guards to make the kitchen fit
https://ozrob.smugmug.com/Army-Camper/Army-Trailer-Camper/i-LrHcVcV/0/M/DSCN0567-M.jpg

Modified wheel arches for the wider axle
https://ozrob.smugmug.com/Army-Camper/Army-Trailer-Camper/i-XZcFRhf/0/M/DSCN0575-M.jpg

Cutting the axle was quite easy as it is hollow in the middle,after cutting the axle, the axle is 48 mm thick but being hollow I welded a length of 1/2" pipe down the middle making the axle 120 mm wider then welded a length of 48 mm pipe over the top so it is just as strong.
https://ozrob.smugmug.com/Army-Camper/Army-Trailer-Camper/i-dSSX8p8/0/M/DSCN0576-M.jpg
Lots of work to make the tailgate, cut the inner guards to fit the kitchen, make the frame for the roof top tent, make the axle 120 mm wider to match the track of the defender and make wider wheel arches.
I am quite happy with the end result after spending many weekends cutting, grinding welding and painting.
Many thanks to Drifta for the ideas....they sell a similar trailer for $7K after all the work I did I understand why.

[debruiser]

Ozrob. U might have made a mistake telling you've done perry much exactly what I want to do. ☺ I might be picking your brains for dimensions and pictures.

Sent from my SM-A300Y using AULRO mobile app

[ozrob]

Ozrob. U might have made a mistake telling you've done perry much exactly what I want to do. ☺ I might be picking your brains for dimensions and pictures.

Sent from my SM-A300Y using AULRO mobile app
For sure mate, happy to take more photos, PM me if you like.
The top of the roof top tent frame is 600 mm above the top of the trailer body. 600 mm is enough clearance for me as I am not tall 170 cm, if you are taller you may need to make the frame height taller or get some block of wood under the wheels.
To fit the kitchen in I had to cut the inner guards, they were originally 430 mm from the edge of the tray now they are 460 mm, the Drifta DSOB needs 450 mm clearance.
The axle track was increased by 120 mm.
The only additional thing i need to fit are stabilizer legs on each corner they need to be able to be extended to 780 mm, so that I can set the trailer up without having the vehicle still attached.

[cactus]

gooday nick. got your pm.. i dont have many pics but ill load a couple to give you an idea as to my set up. the whole rack can be removed if i choose but havnt had the need really. it survived a few corrugations last week no worries. the roof camper is a slightly wider version than most but out of pure luck the rack i had built before the rtc came along was wide enough by 2cm either side.

the mattress supplied took a little getting used to as it is very dense 75mm thick. that plus a sleeping bag and one wool blanket and two pillows saw the roof almost to hard to close. let alone have the ladder in there as well. hence the ladder on the rear of the trailer.

for simplicity i added a tap to the water can on the front of the trailer. best thing ever.

other than that ive kept it simple. just used plastic boxes inside to carry all of our gear. one note is you need to be aware of the gap between top of trailer and bottom of tent capsule as this limits the size of boxes you can get in the trailer. i can easily get a milk crate in but my gas fridge wont go in.. compromise between being top heavy for larger gap or lower for better towing but less gap.

the capsule weighs in at 97kgs. the trailer with all the gear inside travelled extremely well behind the landy as long as you keep it front heavy by around 40kg on the drawbar hitch. i use a pintle hitch for what its worth.

fuel economy dropped from 10 lt per hundred to 12 litres per hundred. at a steady 90kph on the highways

ill add a few pics after i send this as dinner is served.

cheers

[cactus]

pics attached... i hope

[debruiser]

gooday nick. got your pm.. i dont have many pics but ill load a couple to give you an idea as to my set up. the whole rack can be removed if i choose but havnt had the need really. it survived a few corrugations last week no worries. the roof camper is a slightly wider version than most but out of pure luck the rack i had built before the rtc came along was wide enough by 2cm either side.

the mattress supplied took a little getting used to as it is very dense 75mm thick. that plus a sleeping bag and one wool blanket and two pillows saw the roof almost to hard to close. let alone have the ladder in there as well. hence the ladder on the rear of the trailer.

for simplicity i added a tap to the water can on the front of the trailer. best thing ever.

other than that ive kept it simple. just used plastic boxes inside to carry all of our gear. one note is you need to be aware of the gap between top of trailer and bottom of tent capsule as this limits the size of boxes you can get in the trailer. i can easily get a milk crate in but my gas fridge wont go in.. compromise between being top heavy for larger gap or lower for better towing but less gap.

the capsule weighs in at 97kgs. the trailer with all the gear inside travelled extremely well behind the landy as long as you keep it front heavy by around 40kg on the drawbar hitch. i use a pintle hitch for what its worth.

fuel economy dropped from 10 lt per hundred to 12 litres per hundred. at a steady 90kph on the highways

ill add a few pics after i send this as dinner is served.

cheers

Thanks for that Cactus. I've got a Airtop RTT AirTop roof top tent | Autohome Official AirTop roof tent (http://www.autohome-official.com/en/products/hard-shell-roof-top-tent/airtop/maggiolina-airtop-roof-tent) It's a great tent, with all the features you mention but I've never had issues with closing it. Always has a couple pillows, sleeping bags, sheets and the ladder in it when I close it up. I love it - like my own little motel room :D

So you just cut the canvas where your 'roof bars' come up through?

I've been battling with whole how high to make the tent - like you mention, the higher you go the easier it is to load/unload but worse towing. I have about 100mm above the top of the canvas stick or 400mm above the side of the trailer. Hopefully this is an ok compromise. I'm still working on the roof bars though.

My trailer has been converted to a 50mm ball with override brakes. Currently the front of the trailer rides too low, I've got to sort something out to get it sitting more level....

[cactus]

gooday nick

the canvas im still thinking about, thats the one that came with the trailer from auctions so is quite thin and tattered. i can get a new one off ebay made quite local to me for 320 i think but i would need to have the holes cut into it and hemmed properly. then velcro tabs to stop the flapping whilst driving. i have also thought of putting zippers in to make access easier... hard to describe but maybe in about 6 inchs from either end to up near the centre bar that holds the tarp up.. same on other side. might need some light framework to hold things in place. i imagine another couple of hundred to get it how i want. that makes the tarp more expensive than the whole trailer.
my other thought was to make a light weight steel frame replicating the tarp shape and covering that with sheet alloy. bit like a tradesman canopy i guess. it could possibly have canvas glued to the outer skin to keep with original looks and the whole thing could be removed like the roof racks. i could make that myself for less than canvas work.

always thinking .

[cactus]

the roof bars i mounted by cutting 40 mm square holes in the top of the trailer lip so the bars could slide down as far as you want. i let them hang out the bottom of the (tube) about 10mm and placed a tab there for the bar to rest against to remove all chances of movement. then placed a bolt through with locknuts. i also welded a small lug on the tube downframe so that it rested on the trailer top flat to make removing and reinstalling a lot easier. just insured the holes for the bolts lined up perfect without having to align anything

if you need pics i could take some through the week.

the top (H) section is bolted in place at 4 points by sitting in a (cup) lined up with each of the four ends. i needed this framework as the mounting system on the roof pod only allowed for cross bars a maximum of 5ft apart and the original racks i made were 6 ft apart. (the length of the trailer) hopefully the pics explain what i cant.

cheers

[debruiser]

Thanks Cactus. I'm making my bars bolt to the chassis and wrap around the tub so that the canvas is still original. I'm concerned that the ali tub wont stand up to having a tailgate cut in it AND having a roof rack swinging off of it.

Zippers on the canvas would be good but like you said expensive. I thought about going to a 'hard top' but decided against it for 2 main reasons. 1. the lid would hit the tent and reduce the amount of access. and 2. if you have something that sticks up slightly the canvas will still accommodate it - hard top wont. I also contemplated making a ute canopy style top with doors in the sides for access, but I'm striving for a light build.

[debruiser]

A little progress finally! I've almost got the RTT frame made. Needs more paint and a couple brackets on it for the awnings. Maybe a couple holes to secure the soar panel for traveling.

https://lh3.googleusercontent.com/a_DvM_E-m7COLlMz-ROTun3imHzRBZB631x-3qgDdYjDNkt3rEqdIiR4io_sw3B0HNZJSLMnkBUc8kaAiG5Lgb zKe0-xjATNnTf_qC02AO_5mMoc_hgzKyJTHjNGxBwYECUOXXjNGjzgd 2bkHSUuxBNqhfcA5YJ1jHHqy2SbMeENh272FjipiCthwJXXh-mK-60U-TUyj4a6nsNJ8JEzcqcVocNSoGn3EW6h33TYZGD7eQKBuDgaCq9 pM-7KUcE8Y0EwBX3x3YLmTB91olLpXuXiqv-aUjLzrnfwFAqan_1OsEP6F6y8Gp2elhtomTQUCrTb5J4YW0no_ gsUDEjdbyb_ofzKcn4pBF6_WcHEI38zt2lY6WKaVwHJSRRbYEH gk0v15nuPz6h1F9tjoKRiel6DP2FqY42hAqPOCtpyXe1u4i30n CSUwpqpCqhDQFiiSKyZ8Uve-pAxuk2SHP-bD22VWB6UJVSW1z5oBsg7geiNbdy_14dK0YidkdI8YTbc-wjDFoez-dzG3mS-FQpQSsaRNMnmFmp3KusKWQlVZFE=w1676-h943-no

[debruiser]

Ok, well I'm waiting for a mechanic to get here to sort out the brakes for the 88", so I thought I'd do a bit of an update on the trailer.

I got the rtt frame mostly painted (all the underside, only have the top half of the frame to finish off) and installed. That was a little tricky because a) I've made the frame removable ie. it's actually 2 parts that plug together. and b) I tacked it all together - test fitted then pulled it apart to weld out and add the gussets, although i was careful not to heat it all up too much it still pulled a little. :( wasn't a show stopper but a pain all the same.

I'm going to have to weld tabs on to attach the side and rear awnings but I'll do that later when I'm pulling the other camper apart to get all the goodies.

https://www.aulro.com/afvb/images/imported/2015/09/17.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0001_zps8tewv5iu.jpg.html)

Then it was time to cut out the tailgate. I think I spent more time sitting looking at pictures online of other peoples builds then cutting. And definitely more time out in the shed looking at it, walking around it, measuring, scratching my head, thinking of other ways to make a kitchen without cutting the tub up..... than actually cutting.... but here is what will become the tailgate:

https://www.aulro.com/afvb/images/imported/2015/09/18.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0004a_zpsuervrh1u.jpg.html)
https://www.aulro.com/afvb/images/imported/2015/09/19.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0003a_zpswsklv96l.jpg.html)

so then I had to reinforce the gate. A quick trip to bunnings..... some cutting... a little welding (Gas MIG if your interested)... a little grinding (actually I'm using flapper discs, they work heaps nicera on ali)

https://www.aulro.com/afvb/images/imported/2015/09/20.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0006a_zpsbgytjyua.jpg.html)


A little more faffing and I bolted on some hinges. They were a pain because of where they are located, ended up making plates with threaded holes to put inside the RHS.

https://www.aulro.com/afvb/images/imported/2015/11/153.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0008_zps2ikxowf4.jpg.html)

Because I'd cut out a lot of the strength I added a crossbrace. This is also going to be the new home for the canvas bow! that way I don't have to move it to get to the kitchen.
https://www.aulro.com/afvb/images/imported/2015/09/21.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/DSC_0009_zpsqiwohdgj.jpg.html)

[cactus]

its nice when a plan comes together. least with the tailgate you will be able to place larger items in the trailer like the fridge. ive been thinking of gusseting the corners on my framework and will get to it eventually. before the next trip at least im also going to add a side awning where yours is but my framework will be adjustable height. ie awning will bolt to legs that slide up and down inside main legs . just to keep it lower than the rtt when driving but raise above 6ft when camped.

keep the pics coming . you might tempt me to cut a tailgate yet.

cheers

[debruiser]

its nice when a plan comes together. least with the tailgate you will be able to place larger items in the trailer like the fridge. ive been thinking of gusseting the corners on my framework and will get to it eventually. before the next trip at least im also going to add a side awning where yours is but my framework will be adjustable height. ie awning will bolt to legs that slide up and down inside main legs . just to keep it lower than the rtt when driving but raise above 6ft when camped.

keep the pics coming . you might tempt me to cut a tailgate yet.

cheers

yea it is. ahhh yes the fridge.... no it doesn't fit through the tailgate, it goes in through the top, once the tent goes on you can't get the fridge back out.

I have an adjustable awning at the moment (on the other trailer) it's good to keep the weight low, but I just thought I'd go for super simple and light. Everything is chasing light on this build (last camper ended up WAY overweight) well everything is about light and easy to use....

Currently looking at replicating one of those drifta DSO units for the tailgate, but I can't figure out how to build it to 18kgs! a sheet of 7mm ply is 11kg and I'd need 2.5 sheets... so that'd be closer to 30kgs. Not sure what to do there yet.

[SG1 Bones]

What welder are you using for the aluminum welds?

I'm really enjoying the coming together of the trailer. I'd be too scared to cut anything like the tail gate off, so good on you for taking the plunge.

Nathan.

[debruiser]

Hi Nathan, I'm using this Lincoln Electric (http://www.lincolnelectric.com.au/products/page350/category1/category18/power-mig-180c)

I just use a tip that is 0.2mm bigger than the wire ie, 1mm wire and a 1.2mm tip. I'm not using the ali spool handle thingo for an extra $300 or whatever, I did inquire about it at the local welding shop but they said not to bother. They gave me a couple pointers:
- use the oversize tip
- keep the gun cable as straight as possible
- minimal pressure on the feed wheel
I have to have the welder fairly cranked up to get it to weld nicely. I haven't hit the duty cycle though.

I am naughty and am using stainshield instead of Alushield. I first tried it because I had got the bottle of stainshield to weld up an exhaust and thought I'd try to use it rather than return a 3/4full bottle. Plus Alushield is like 3x the price.

O, I was scared about cutting the tailgate out!!!! And I still am concerned; will only be happy with it when I do a few trips and see that 1) there is minimal dust ingress, 2) the tailgate doesn't fall off, 3) the sides don't fall off.

[51mondays]

Great thread thanks for sharing the build. Looks fantastic. Yeah I'm looking to buy or build a camping trailer and like the light weight idea.

Do you know what the overall weight is yet?

[debruiser]

I have no idea of weights yet. Ballpark figures so far would be:

Trailer (bare) 350kg? (does that sound right RAAF people?)
Rtt frame 15kg
Fridge (empty) 30kg
water tank (empty) 20kg
Water for in tank 70kg
DSO swing out kitchen 18kg
gas bottle (full) 9kg
camp cooker 3kg
2x100amp deep cycle battery 58kg
RTT airtop tent 60kg
Side awning 10kg
rear awning 10 kg
TOTAL: 652kg.

Other stuff will go in, like a water pump, solar panel, electrical gizmos and the like. So if we call it 700kg then I've got 50kgs room for chairs and 'camping stuff' before I hit the golden 750kg max (for rego).

That would be almost half my current setup! but I do loose my 80L diesel tank from the back.

[4runnernomore]

Currently looking at replicating one of those drifta DSO units for the tailgate, but I can't figure out how to build it to 18kgs! a sheet of 7mm ply is 11kg and I'd need 2.5 sheets... so that'd be closer to 30kgs. Not sure what to do there yet.[/QUOTE]


Can you make the same design out of aluminium sheet and aluminium frame (cube lock perhaps) instead to keep the weight down?

[debruiser]

Currently looking at replicating one of those drifta DSO units for the tailgate, but I can't figure out how to build it to 18kgs! a sheet of 7mm ply is 11kg and I'd need 2.5 sheets... so that'd be closer to 30kgs. Not sure what to do there yet.


Can you make the same design out of aluminium sheet and aluminium frame (cube lock perhaps) instead to keep the weight down?[/QUOTE]

that thought had crossed my mind, and I could possibly just weld the frame onto the tailgate - using the tailgate as part of the structure. But i was worried that the price would be prohibitive..... maybe I need to look into it more - figure out what I would need and how much it might really cost

[debruiser]

So I've been contemplating how to 'crank' my draw bar on the No5 so it rides level behind the defender (or behind Seth/Loki/Red/Blue/that thing depending on who is referring to it :) - the series). Was trawling through old posts on the forum today and came across this one :
http://www.aulro.com/afvb/military-trailers/204915-fitting-no-5-trailer-disco-1-a-2.html#post2238452
and
http://www.aulro.com/afvb/military-trailers/210412-sitecs-trailer-3.html#post2276513

I was thinking if I used a similar idea to lower the hitch height as Petetheprinta did but probably 75mm?and then move my brake master to a similar config that Sitec did.

Nerdy engineering questions now: What thickness steel should I use? I have some 10mm plate I could use for the vertical and horizontal then get some 6mm plate to brace vertically similar to what Sitec has done? OR is 6mm all over enough?

[debruiser]

Did some cutting and welding.... grinding... head scratching... painting and I have modified my no5 liek this:

https://www.aulro.com/afvb/images/imported/2015/11/1019.jpg (http://s1295.photobucket.com/user/debruiser/media/DSC_0004%20copy_zpsdvrtouzi.jpg.html)
The nose is still a little down... but I thought that was a good excuse for a lift and big tyres :)

https://www.aulro.com/afvb/images/imported/2015/10/611.jpg (http://s1295.photobucket.com/user/debruiser/media/DSC_0003%20copy_zpsnqsdqij1.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/06/225.jpg (http://s1295.photobucket.com/user/debruiser/media/DSC_0002%20copy_zpssjiuicqz.jpg.html)
i've cut the handbrake lever and moved it to 90deg from vertical so that it doesn't stick up higher than the master cylinder! That way the door wont hit it - was a PIA not being able to open the door with the trailer hooked up.

https://www.aulro.com/afvb/images/imported/2015/10/612.jpg (http://s1295.photobucket.com/user/debruiser/media/DSC_0001%20copy_zps2t6up3bp.jpg.html)
With the short extension it's now possible to open the door :)

[SG1 Bones]

The trailer looks great. What colour are you thinking of painting it?

[debruiser]

The trailer looks great. What colour are you thinking of painting it?

Yea it is starting to look a bit patchy now isn't it.... :D I was thinking of returning it to auscam, when I'm finished altering it.

[SG1 Bones]

That would be great. I personally like seeing No. 5's being towed in their original colors.

[Mick_Marsh]

Yea it is starting to look a bit patchy now isn't it.... :D I was thinking of returning it to auscam, when I'm finished altering it.
I'd paint it the same colour as the 90.

[debruiser]

I'd paint it the same colour as the 90.

that is a good idea.... I'm going to tow it behind the blue beasty too though. So I will have to think about it. I could paint it blue to match the blue car, i've got some paint but I don't really like hte blue anymore...

[John H]

Thanks for the thread.great info.Paint the 90 camo to match the trailer;).You may never be seen again :o

[debruiser]

Thanks for the thread.great info.Paint the 90 camo to match the trailer;).You may never be seen again :o

Funny you should say that. Was down at bob jane the other day picking up wheels with the 90 and trailer, the guy who served me said exactly the same thing.

I do think the 90 would look awesome in Auscam, but then again so would the 88". The 88" might just get the ol' paint brush treatment yet :D

[John H]

Funny you should say that. Was down at bob jane the other day picking up wheels with the 90 and trailer, the guy who served me said exactly the same thing.

I do think the 90 would look awesome in Auscam, but then again so would the 88". The 88" might just get the ol' paint brush treatment yet :D

Forget paint brushes.I used 9x cans of spray paint(3xcam green,3xblack and 3xtan)from Protec when I spruced up my 110 gs.Prep work is the worst bit of the job and then you get to graffiti your own vehicles:cool:

[debruiser]

So we are planning on going camping at easter, so I thought I should get in and finish/or attempt to get to a useable state the No5 camper. So I've been making the kitchen shelving in the back. Tomorrows job is to make a fold down bench on the tailgate.

https://www.aulro.com/afvb/images/imported/2016/03/796.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/20160305_154859_zpsrrpw2gip.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/03/797.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/20160305_165414_zpsghyx2dap.jpg.html)

[debruiser]

Kitchen is almost complete. Just need to sort a locking mechanism to hold the tailgate open.

Did some painting the other night. Was too slack/in a hurry to wait to order 'proper' Auscam, and saw some rustkill in satin and colours that at first glance looked close enough for me, pity the green is too light! At this point in time it will have to do because I dont have money or time time redo it.
https://www.aulro.com/afvb/images/imported/2016/03/592.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/FB_IMG_1457666219398_zps7nhnkjc0.jpg.html)

Did some wiring, all the gizzmos are scavenged from the old camper trailer, as is most of the wiring.
https://www.aulro.com/afvb/images/imported/2016/03/593.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/20160311_165514_zpsrc4ivjj6.jpg.html)

O, should mention that the blue panel is blue because it's the footwell off my series build.... I've replaced the standard series footplates with county ones so these were spare and happened to be the right size with the knobby bits chopped off! (yes it's a budget build)

https://www.aulro.com/afvb/images/imported/2016/03/594.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/20160311_165535_zps8eblisiu.jpg.html)

The fridge is not riding there, it's just pushed over so I could mount the inverter, once the fridge is in place there is VERY limited room to access the inverter.

[Corgie Carrier]

Great lookin job and very well laid out electrical board.

One suggestion, if the electrical board stays in that position, maybe put some covers over the white power points to stop the dirt/dust getting in them and stuffing them. Seeing as it is a budget build, you could use the lids off aerosol or spray paint cans.

[debruiser]

Great lookin job and very well laid out electrical board.

One suggestion, if the electrical board stays in that position, maybe put some covers over the white power points to stop the dirt/dust getting in them and stuffing them. Seeing as it is a budget build, you could use the lids off aerosol or spray paint cans.

Thank you for the compliment... working as a TA in an industrial electrical workshop for 18months must have taught me something :)

Yea the board stays like that. I had thought about dust and grot getting into those points.... I'll be using the standard canvas cover over the trailer and that seems to keep a whole lot more dust out than you'd expect. I like the aerosol can idea for now, but later when I get money and time I do agree that it'd be good to come up with some sort of dust cover.

My other concern was water ingress while camping. I think I might have to come up with some sort of skirt style thing that catches the drips from the RTT and runs it off onto the awning. Probably doens't make much sense atm.... I'll post a pic when I get the tent on then all will become clear!

[debruiser]

Another big day (after I mowed the lawn like I was told I had to). Got in and finished off the wiring for V1 of the camper. So now I have solar AND car charging (yet to install the plug on the car), also have all those power outlets, plus inverter, 1 worklight shinning out the back and 1 general light over the camper. V2, will include 2 more worklights (if the 1st one is ok), a water pump and probably other stuff I can't think of atm.

Still have to fit the rear stabilizer legs and tie the fridge down but that is pretty much it for V1, other than throwing all the camping gear in. V2 will have a water tank slung under there somewhere (suggestions from experienced minds welcome). Plus some water/dust protection for the electrical compartment and a 2nd battery! (made it ready to carry 2 just dont have 2 yet).

Does anyone know if the authorities would frown on hanging a gas bottle off the tailgate??? would be convenient for use and weight distribution.

https://www.aulro.com/afvb/images/imported/2016/03/582.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/20160312_170504_zps6umkmdfi.jpg.html)

You can see that I'm feeling pushed for time by the "cleanliness" of my shed. haha

[cactus]

yours is coming along nicely

[debruiser]

yours is coming along nicely

Almost twins, except you must have something really heavy in ur trailer to stretch ur 90 out like that :P , my kayak is green, and my mrs wont pose with my defender like that :(

Do you find the trailer still tows ok with the weight of that tent up high? AND a photo of your back end (trailer preferably) haha. thanks

[cactus]

ive had no issues with the trailer balance. i do however make sure i have about 30kgs of weight on the tow hitch. i can cruise at 110kmh and dont know the trailer is there . but if i cruise at 90kmh i still get 10 ltrs per 100 average on the highway.

ive got so many pics with the mrs posing by the landy i could start a magazine.

ill see if i can find a back end pic. note my trailer is still a sealed unit. i just lift everything i need over the sides.

cheers cactus

[debruiser]

ive had no issues with the trailer balance. i do however make sure i have about 30kgs of weight on the tow hitch. i can cruise at 110kmh and dont know the trailer is there . but if i cruise at 90kmh i still get 10 ltrs per 100 average on the highway.

ive got so many pics with the mrs posing by the landy i could start a magazine.

ill see if i can find a back end pic. note my trailer is still a sealed unit. i just lift everything i need over the sides.

cheers cactus

I went with the tailgate because a "kitchen" was on the mandatory list given by the mrs.

I was interested to see what was hanging off the back of your trailer... thought it might be a jerry can or something but only a ladder. My tent is sitting forward pretty much flush with the leading edge of the spare tyre so my issue will be getting enough weight to the back of the trailer. Have you got a water tank inside? Am I correct in thinking that you have no stablising things on the back of the trailer so you only sleep in it with it hooked on the car?

[cactus]

always sleep with the trailer attached to the car. it was the easy option compared to fitting rear legs. i do have a workshop chassis sitting here that has shockers and rear legs already on it. i believe i can simply unbolt the box unit and swap chassis over. its on my to do list along with lengthening the draw bar 12 inches before i do the swap. the photo above by the beach was the first trip with the 16ft canoe on top of the car. i was worried when travelling through the sand dune area of robe SA that the canoe might land on the camper top and it did :( limited our adventure somewhat. i do have a 12ft canoe but its just a one person but i have no overhang problems. i think the extended drawbar is the way to go. just finding time to do it.
as for water i just carry 20lt army issue(being thicker plastic than most) jerry cans. i have 4 and pending on where i place them in the trailer i can adjust my towbar weight to what i need. the undercarriage of the trailer doesnt lend itself to well for an under chassis mount having the round drawbar running full length as you would be well aware.
in the back of my mind i do recall a caravan tank that has a recess running through the width of it. if luck was running your way it might allow you to mount the tank closer to floor level.

ill keep an eye on #bay and if i see the one im thinking of ill send a link for you to look at.

cheers

[debruiser]

After lots of hours in the shed I've finally reached V1. Took it for a quick spin to see how it tows; feels ok so far. MUCH lighter than the old camper. I recon this thing would struggle to be 500kg without camping gear!

https://www.aulro.com/afvb/images/imported/2016/07/299.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/20160318_160001_zpsmbp0aik7.jpg.html)

https://www.aulro.com/afvb/images/imported/2016/03/377.jpg (http://s1295.photobucket.com/user/debruiser/media/No5%20Camper/20160318_155937_zpspuzu3p9l.jpg.html)

[Tank]

Was wondering if you stayed with that 50mm tow ball hitch or fitted a proper off road hitch, Regards Frank.

[debruiser]

Was wondering if you stayed with that 50mm tow ball hitch or fitted a proper off road hitch, Regards Frank.

Frank, no I'm staying with the 50mm ball for now.... budget has closed on this build for now.... later when I get some more money I'll get a water tank, awning, and maybe a offroad hitch

[weeds]

50mm ball articulates more than most think.......

[debruiser]

50mm ball articulates more than most think.......

well yea, it's a override unit so the hitch can turn 360deg.... thought I read somewhere that the standard 50mm ball had 15deg in each direction from horizontal.

[Homestar]

50mm ball articulates more than most think.......

Indeed it does. Although I looking to get rid of mine as I don't like them as they don't lock as well as some others, I've taken my van over some very uneven ground without binding issues. I think I've come close at times though.

My van isn't an off-road van though, but I do the it off road - not like over 100's of KM of corrugatuons, but into the bush down a couple of KM of tracks to get to where I want from time to time.

[Smcconnell]

Hey mate, are you open to selling the trailer? I need one on short notice, willing to pay decent money.

Steven

[debruiser]

Hey,
Na it's a work in progress still and the MRS wont go out camping without one.

Try Gumtree, I see there was at least one in the Mackay area on there just the other day!