No.5 Camper trailer build

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.

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_...=w1676-h943-no

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/im...2015/09/17.jpg

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/im...2015/09/18.jpg
https://www.aulro.com/afvb/images/im...2015/09/19.jpg

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/im...2015/09/20.jpg


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/im...015/11/153.jpg

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/im...2015/09/21.jpg

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

Quote:

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Originally Posted by 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

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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.

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.

Hi Nathan, I'm using this Lincoln Electric

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.

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?

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.

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?