SeaDooDAN's trailer build thread

[dgoodwin10]

I figured I would start documenting this build early, since it's still in the planning stages. Some of you may have seen my '96 XP build, found here: http://www.seadooforum.com/showthread.php?71268-SeadooDAN-s-96-XP-build-thread

I got this trailer on that deal and aside from some usual wear and tear things, its a great little trailer to the normal person. But when it comes to trailers, I don't know how to leave well enough alone. I would consider myself a 'hobbyist' welder and I've built a few utility trailers from the ground up in the last few years, and though this one isn't quite that extensive, I have some big plans for it. Now, onto some pictures of my next...victim.

I'll have some better pictures of the trailer later since its back home while I finish up classes this summer. And yes, I am a college kid, so this will be done on a budget.

The best I can tell, this trailer was used to haul a pair of 3 seaters, judging by the winch position, which brings up my first issue. This trailer will be toting a GTX and an XP, so the XP will be sitting pretty far forward on the trailer. The current winch system is totally adjustable and works well, but it isn't the cleanest system ever, nor does it accommodate 2 different skis very well. It also is running 8" tires, which have got to go. I know they would probably be fine, but I would feel much more comfortable with some 12"s, which would also match my single trailer that the GTX is currently on and allow me to run a single spare. The trailer also has no storage, which is probably the biggest issue. i want a place to keep life jackets, oil, gas, tools and all that junk. So with all that being said, here is my current modification list on this trailer, in no particular order:

First, I'm going to order new hubs and wheels to fit my current axle and swap those on. I'm going to pull the winch assembly off and weld in new cross members to accommodate a different winch setup, very similar to the Shoreland'r and iMove trailers. (I'll post a picture when PB is back online). And now comes the big one, which will happen before the winches: making room for storage. With a different winch system, I might have room to clear the toolbox, which I already own, but I'm not counting on it. My plan is to cut the frame right in front of the axle and add up to 2' to this thing. Don't worry, after I box in the channel and plate the outside, it will all be fine. For mounting the toolbox, I'll make a frame out of angle iron that will be welded to the trailer and the box will sit in and bolt to. Last, it will get new bunks, a walk board, lights and who knows...maybe a few other surprises! So, stay tuned for this build. I'm definitely excited about it. Questions, comments, jokes and criticism are always welcome.

 

[dgoodwin10]

I figured I would need to post up what will be pulling this trailer most of the time. Here is my '03 Silverado, that has been in the family since new. Its got the 5.3L V8, built 4L60E, 285 Toyo AT 2s, Rough Country lift, Mile Marker winch, on board air, 9.5" 14 bolt rear axle from a 2500 with 4.10 gears, Pioneer radio, 2006 hood and grill (thanks to another guy's insurance) and a few other goodies. This truck started as a bone stock 2wd when I got it 6 years ago and has been a work in progress ever since (yes, there is a front axle swap and 4wd conversion in its future). I use this truck for trips, towing, on job sites and everything in between, and I wanted it build to do anything I threw at it, and that was my goal from the start: Functional. So, here's a few pictures, and yes, I need to paint my camper shell:

 

[dgoodwin10]

It’s finally time to get this build thread rolling! I knew from the start that I wanted to have storage for gas cans and a tool box, so I decided to build this trailer from front to back to make sure everything fit like it needed to. I started by taking off all the original winches and bunk mounts, and by taking I mean breaking every darn bolt on this thing thanks to rust.

And speaking of rust: this will ride, right?

Having built a few previous trailers with tool boxes, I already knew the tongue length I needed for the box to clear the truck. With that measure off, I began by laying out the frame for the toolbox to sit in since I had it to measure off of. And just a note here: I know some of you that are welders are seeing a galvanized trailer and freaking out at me welding it. Don’t worry, as that has been taken into consideration. This is actually galvanizing paint which is a safer ball game that the real thing, and all necessary precautions have been taken to avoid any hazardous situations.

I then set 3 gas cans next to each other and made a spot for those to sit.

The gas can storage will be getting hooks for straps.


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[dgoodwin10]

Next came the fun part. I did some measuring on an existing winch setup I am copying, added 8” for a walk board then measured back to the rear of the GTX, since it’s the biggest ski that I own. From here, I subtracted about 10” so that the bunk support moved closer to the CG of the ski, but still letting the bunks themselves run the full length. With measurements in hand, I grabbed the sawzall and went to work.

My numbers came up with needing to add 42” to the trailer and here is one of the frame extensions that will be going in.

Now it was time to weld on the extensions, so the joints were ground smooth and beveled in order to get a good weld on them. Using a piece of angle iron as a straight edge, we clamped it on the trailer and used it as a jig to fit each side.

Quite a change from what it was! This was before I moved the axle. I also plated the frame and added an additional cross member at this point that would serve as the mount for the front bunk brackets. This dimension was also pulled from an existing trailer.

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[dgoodwin10]

Now it was time to move the axle to the correct location. With the fenders cut off, we flipped it upside down and got to cutting. After some measuring and calculations, we determined an axle centerline and welded in the new hangers.

With my previous luck with U Bolts,I decided early that I wanted to avoid using them. After some more measuring and a using the hoist to set the ski in place to double check, we welded on the first set of tabs for the bunks. Using a 2x4 on a pivot mount, we needed 3.5” of height on the tabs above the frame to get the ski to sit where we needed. This was the result.

With 1 side down and fitting properly, I welded the other side on and set the skis on for a test fit.

I never realized how small the XP is next to the GTX! Its tiny! At this point, I am beyond stoked since this is a setup that I have been wanting for years. Seeing them both on the trailer was an awesome sight. I pulled the skis off early this week and have been working on finish welding everything up to this point. That’s where it sits as of now. I need to fabricate winch mounts and put the fenders back on, so I still have work to do.

Stay tuned! More updates are coming soon!
Questions and comments are welcome.


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[Mickirig1]

Too kool project ! I am ready to add a tool box and duel gas can holder to my twin Shorelander trailer. I have alot of space to do it.

 

[dgoodwin10]

It's update time! I worked like crazy to get the XP and trailer ready for last weekend and We made it. Time to catch y'all up on how I got there. The runners are simply 2x4" treated lumber wrapped in outdoor carpet from Home Depot and fastened with stainless staples. At $1.50 each, I bought brackets from Academy to save the time from having to make them. The length was a slight modification from a shore lander trailer.

You saw the gas can rack started, but it needed to be finished. I had a spare piece of mesh left offer from another project, so we measured and got to cutting.

I still need to ad some tie downs for holding the cans in, but for now hooking to the mesh will work just fine. I still have a lot of room left on the rack, so I may work out some storage around the cans, but that is still in the planning stage. Next was on to fenders. I wanted a mount substantial enough to stand on, so again I turned to the scrap pile and got some 1"x3" tube and welded it on the trailer for the base of my fender mounts.

The fenders will sit on top. The end goal will be to add another piece from the frame to the fender mount to make a step, much like on boat trailers.

With the skis on the trailer, it was time to work on the winches. I had done a lot of looking and measuring and this is what I came up with

I sliced the end of the tube open and bent it out to catch the roller, which worked well. I added the stock to the back to prevent the main tube from pulling off the mount.

With all the mandatory systems in place and the lights wired, I loaded the skis up and packed the trailer.

This trailer is a long way from done, so plenty more updates are coming. Everything went well this weekend and it pulled great. The toolbox was also a handy addition to keep all the junk in that usually goes to the lake like oil, tools and jackets. I do know that walk boards are next on the list, followed by a paint job. Stay tuned for more as I still have a few tricks up my sleeve!


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[Mickirig1]

I saw a trailer in Cleveland that had a way to lock the gas cans to the trailer. He had a straight pipe that went thru brackets at each end. With the pipe going thru the gas can handles in the middle with a pad lock to secure them. The other end of gas cans had another pipe with pipe insulation wrap to lock them into the bracket. No bungie cords. Simple but Genuis! Gotta love clever guys in the USA!