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What's This!? Another Project!?
Tinker Sitting On First Piece To Be Cut.
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Main Frame Is 2"X3"X.120" Wall Steel Tubing. All Corners Mittered To 45 Degrees.
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All Four Sides Tack Welded And Squared.
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Two Center Pieces Cut And Positioned At Spring Mounting Location.
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Gussets Were Cut From 1/4" Steel Plate And Placed At Spring Hanger Locations.
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Spring Hangers Were Checked To Be True, Cleaned, Then Welded In Place. All Welds On Frame Were Made, And Frame Was Turned Right-Side-Up.
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All Welds On Frame Were Smoothed Before Starting On Side Rails.
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Side Rails And Floor Braces Were Made With 1 1/2"X.120" Wall Square Steel Tubing.
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Tail Gate Was Also Made With 1 1/2"X.120" Wall Square Steel Tubing.
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Tail Gate Hinge Mounting Pads Made From 1/8" and 3/8" Steel Plate.
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Pads Were Used To Give Extra Thickness For Bolt Threads That The Hinges Will Be Mounted To. The Side Rails And Gate Were Placed 1/4" In from Outside Edge Of Frame.
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Hinge Pads Were Welded To Gate And Main Frame Before Being Tapped 1/4"-20.
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Test Fit Was Made To Check Correct Placement Of Gate With Hinges Installed.
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Pieces Were Rough Cut For Gate Latch Hardware Using 1/4" Stainless Plate.
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Pieces Were Welded Together...
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And Finished With Holes Made To Attach Stainless Cable And Latches.
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1/2-13 Expanded Metal Was Cut To Fit Floor And Left And Right Side Rail. Each Contact Point Around The Ends Were Welded Using Stainless Rod.
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Prior To Welding Expanded Metal To Side Rails, Stainless 5/8" Bar Was Welded In For Tie-Down Points.
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Expanded Metal Was Cut To Stagger Welds At All Corner Locations.
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The Bottom Edge Of The Front Section Was Bent 90 Degrees To Give More Surface Area For Welds.
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Many Clamps Were Used To Hold The Metal In Place Prior To Welding.
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Both Floor And Rail Expanded Metal Was Also Staggered To Give A Stronger Fit.
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After All The Expanded Was Welded,
The Gate And All Measurements Were Checked To Be Correct And Square.
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All Paint Was Removed From Springs And Axle. Spring Pads On Axle Were Removed And Repositioned. Shock Bracket Locations Were Checked Also.
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Shock Mounting Brackets Were Made From 1/4" Steel Plate And Welded To Axle And Frame.
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Wheels And Tires Were Placed Temporary To Measure For Fenders.
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I Wanted The Fenders To Be Heavy Steel Diamond Plate. No Ready Made Fenders Could Be Located To Fit This Size Tire! A Final Design Was Made And A Layout Drawn For Angle Cuts To Fabricate.
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A Rolled Edge Was Needed On The 14GA Metal Pieces I Ordered. A Trip To Cleveland Metal Works And A Talk With A Friend Got The Edges I Wanted!
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After Several Hours Of Making Mitter Cuts And Welding The Fenders Took Shape! Each Fender Had 7 pieces of Diamond Plate Fitted To The Flat Back Plate Welded And Finished.
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The Four Side Bars Were Fabricated Using 1 1/2"X.120" Square Steel Tubing. A Layout Was Made And Angles Cut On The Tubing.
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The Side Bars Were Welded And Finished, Then Welded To The Frame.
The Bars Also Provided A Strong Attachment Point For The Fenders.
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Tail Light Brackets Were Designed And Fabricated Using Stainless Plate And Square Tubing.
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Square Tubing Was Used So The Electric Wires Could Be Run Inside Without Being Exposed.
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"For Looks", The Ends Of The Brackets Were Made Round.
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Sheet Metal Of The Same Thickness Was Cut And Fit To The Top End Of Each Tube.
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Each Bracket Was Drilled With Needed Holes For Mounting The Lights, Welded And Finished.
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Several Different Designs Were Made For The Off-Road Hitch. It Needed To be Strong And Work With The Jeep As A Single Unit!
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The Main Tube Is 3"X3"X1/4". Both End Plates Are 3/8" And The Round DOM Tubing Is 1 1/2" with 1/4" Wall.
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The 1" Round 1018 Shaft Was Cut With A Shoulder On The Yoke End For Better Alignment.
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The Back End Of The Shaft Was Threaded 1"-14. A Place For A Grease Fitting Was Also Made In The 1 1/2" DOM Tube.
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Both Yokes Were Made Using 1/2"X2" CRS Flat Bar.
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I Found A 3"X3"X11" Grade 95 Polyurethane Bar On Ebay At Half The Price Of Mill Price! I Only Needed A 4 1/2" Long Piece. The Price Was Much Better Than A Special Cut-To-Order Factory Piece... Oh, They Sell It By The "Inch" At About $6 Or $7 Per Inch!
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The "Joint" Was Finished Complete With Steel Sleeves For The Two 5/8" Grade 8 Bolts.
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This Is The Three Pieces That Make The Off-Road hitch Work.
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A Test Fit Proved To Be Good!
Yes, The Nose Of The Trailer Is Very Strong!!
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I Wanted The Jack-Wheel To Be Simple, Strong, Work Every Time,
Lock In Both Up And Down Positions, No Noise, Not Rust Away... Couldn't Find One, So I Designed And Made One!
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The Main Part Was Made Of Stainless And Stops Were Made For The Folded And Down Positions. The Hex Head Bolt Was Replaced With a Button Head Stainless Bolt.
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The Caster Wheel Is For A Much Larger Trailer. It Was Used Because The Wheel Is Much Wider Which Will Make It Easier To Use Off-road.
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The Base Plate Was Welded Solid To The Front Section Of The Frame... It'll Be There When Needed, For Sure!!
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The Trailer Just Had To Have A Bumper!! Ha!
It's 2"X3"X.120" Stainless. I Found A Piece 48" Long, But The Bumper Needed To Be 52" Wide! So I Had To Add An Extra 2 Inches To Each End. I Could Have Made The Ends Square? Because No One Will Ever Know The Angles I Used Match The Angles Of The Rear Side Bars!
Crazy! Who, ME!?
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Almost There!!
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FULL CIRCLE!!
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Yeah! I Got All Them High Dollar Fabricating Equipment! Well, I Do Have A Milwaukee Porta-Band, 1/2" Drill, 4 1/2" Grinder, And An Old Miller Welder... And Also One Old 1993 Chevy Van Brake Rotor!
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If You Think This Was Easy.. Try It!
The Small Side Of The Rotor Made The Base For the Propane Tanks, The Large Side Was Used To Form The Larger Rings. Metal, 3/16"X1 1/2" Stainless Flat Bar.
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The Large Rings Lock The Tanks In Place Using A 1/2" Stainless Bolt.
If You Decide To Steal A Tank, You'll Need A 3/4" Scocket With An Extension, Or You Could Ask To Borrow My Lug Wrench, Which Fits All The Lug Nuts, Which Fits The Trailer And Jeep Jacks, And Also The Bottle Rack!
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The Fenders With The Primer Coat Of Imron.
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Axle, Springs, And Parts Received The Imron Too! The Trailer Has Already Received The Last Coat Of POR-15. My Camera Doesn't Show Good Color In The Basement For Some Reason.. But, I'm Not Good Color Down There Either!! Ha!
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