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 The Orange Trailer Build thread... 
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Mud Mad
Mud Mad

Joined: Fri May 14, 2010 6:48 am
Posts: 377
Karma: 1

Location: Ferndown, Dorset
My Vehicle(s): 2.0 Grand Vitara
Post The Orange Trailer Build thread...
Hi all.
As many of you know, i am partial to making Green laning more interesting by towing a trailer.
These trailers have taken a few forms over the years...
The Mk1 Green box trailer...
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This was constructed using a modified caravan chassis, with a re-purposed military container that was scrapped off from my work.
This also used the trailer axle, which had those weird rubber bush suspension units, which meant at the weight it was it had nearly no suspension.
I bounced around a gooden, and pummeled anything inside it. It saw quite a few outings, but was alas destined to be replaced.

The Tiny Caravan AKA 'The Coffin'
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Th mission for this was to allow me to sleep inside it, and carry all the gear and tools necessary for laning, so that the car was empty with space for passengers, and didnt sit too low on its axles.
It had onboard power via a lead acid battery, lighting, charge sockets and a fridge.

It had a pupose built chassis, to sit atop a Saxo axle.
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This had a fantastic ride, better than the car. Soaked up all the bumps and handled many a trail.
Including the Bomb Hole on the Strata... https://photos.app.goo.gl/mTjEeLXJyuwNT9uG9

Unfortunately, the ply that i used to construct it (Biol proof exterior ply) and the fact that it was covered in epoxy resin, the ply started to de-laminate, so it went to the great scrap yard in the sky... :(

That lead to the hybrid Mk2 Green Box Trailer, using the box from the first on the chassis of the seccond.
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This was also used on many trails, and was reluctantly sold.
And so followed a year or so without a trailer.

Then i saw something from our Ozy bretherin from across the water.
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Some of you may be familiar with these trailers, and although they are super over equipped, mainly for the extreme ozy bush, i really liked the style and idea of the whole setup.
What i didn't like, was the over all weight, at 680kg for the little X2, it was a little on the heavy side for a little GV to handle.
So i set about the idea of an all Aluminium version, albeit a little on the cut down side, equipment wise.

The plan... To make a trailer from Aluminium, using a riveted and bonded construction technique, building a monocoque structure to contain drawers and stuff inside, with a roof tent on the top.

So following the purchase of a 106 rear axle, to use as a start point, i started to lay out the design...
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Coming together... Not sure i wanted that big a box on the front though. Might get a bit on the heavy side.

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By this point the assembly of around 1200 rivets with only a pop rivet gun was starting make my arm ache...!

Some sheet metal arches made from 3mm aly...
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Painty Painty... Acid etch primer (dont get it in your eye... stingy stingy...)
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Then the application of 2ltrs of Black Raptor Polyurethane Bed-liner Paint.
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Tough stuff, and its what the bumpers on the GV are painted with...
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Then time for the box to be painted...
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Masking taken of before it hardens...
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Time for some lights and other necessary bits...
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Complete with slide out kitchen and fridge slide...
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Please ask any question you like, happy to talk through any bit of the build.


Thu Aug 02, 2018 5:06 pm
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MUD NUT
MUD NUT

Joined: Fri Feb 26, 2010 12:50 pm
Posts: 2569
Karma: 55

Location: 'Laning-Heaven (Waleshire)
My Vehicle(s): Modest Lil' Jimny ;)
Post Re: The Orange Trailer Build thread...
Fabulous! :ymapplause: ^:)^


Tue Aug 07, 2018 3:36 pm
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Mud Mad
Mud Mad

Joined: Fri May 14, 2010 6:48 am
Posts: 377
Karma: 1

Location: Ferndown, Dorset
My Vehicle(s): 2.0 Grand Vitara
Post Re: The Orange Trailer Build thread...
Cheers Dave. I do try.

Although there's plenty of little points and details that i would change now...
Keep an eye out for the Mk2.. :lol:


Sat Aug 11, 2018 4:40 pm
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Mud Mad
Mud Mad

Joined: Fri May 14, 2010 6:48 am
Posts: 377
Karma: 1

Location: Ferndown, Dorset
My Vehicle(s): 2.0 Grand Vitara
Post Re: The Orange Trailer Build thread...
A bit of an update...
Managed to pick up a roof tent for the trailer.

Got to be a few years old, but it looks like its been well cared for.
Needs an extra layer of foam under the mattress for my liking, but i think ebay will come to the rescue.

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This is the first time i have had any experience with roof tents, and i must say i'm impressed.
Got loads of room, I'm 6Ft 3, so tents can be a little tricky when it comes to head room.
Loads of windows and nice and light approx 35kg...

Cant wait to use it in anger...


Sun Aug 12, 2018 3:53 pm
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Mud Mad
Mud Mad

Joined: Fri May 14, 2010 6:48 am
Posts: 377
Karma: 1

Location: Ferndown, Dorset
My Vehicle(s): 2.0 Grand Vitara
Post Re: The Orange Trailer Build thread...
So the trailer has now been used in anger, and some learning has been acomplished...
Having the fridge slide out on rails is awesome, makes it so accessible. However... this now makes the space behind the fridge (the throw stuff in space) rather tricky to get to, really nessesitating the removal of the fridge.
Solution...?

Move the fridge to the front of the trailer and cut a new door in to the side.
So construction of the door took place, followed by the moving of the fridge slide mechanism to the front left...
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Door location on front left of trailer...
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Fridge all tucked away...
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Fridge slides out to access the beverages...
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Advice needed...! What colour to paint the new door, orange like the trialer body...? or black like the fittings and other door on the side..?


New storage shelf in the rear of trailer where the fridge once resided.
Sorry for the exposure, blazing sunshine...
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And second slide out drawer, this one for general stuff...
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Sun Sep 02, 2018 1:08 pm
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A very Special Boy
A very Special Boy
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Joined: Mon Jul 19, 2010 12:07 am
Posts: 1443
Karma: 9

Location: Nottingham
My Vehicle(s): The Old G.O.A.T.
Post Re: The Orange Trailer Build thread...
Dude, that thing is looking so professional, nice job. Looking forward to seeing it.


Sun Sep 02, 2018 1:25 pm
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