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listerdiesel

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Reply with quote  #1 

Philip has had this trailer for 3-4 years without getting stuck into it, but things are moving now, hopefully. The body is off and he pressure washed the chassis yesterday.

The plan is to extend the chassis by 600mm at each end and build a camper body onto it.

I'll post some pictures as we go along, bodywork will be Aalco extrusions again, similar to the 6-wheel drawbar trailer.

Sankey15.jpg

Sankey16.jpg

Here we go:

Philip starts cutting through the rear chassis members, note that he always wears goggles, it isn't for show and it isn't a posed picture, you can see the sparks round his feet if you look closely:

[Sankey31]

[Sankey18]

I'm helping, and wear safety glasses all day:

[Sankey20]

[Sankey21]

Bit of a bob-tailed look about it now!

Getting the pre-cut extension pieces in place and lined up, using another piece to act as a splint:

[Sankey22]

Our Oerlikon MIG welder, family owned, not the company's:

[Sankey23]

Both legs on the chassis, now to get the back frame attached again:

[Sankey24]

[Sankey25]

The chassis isn't welded yet, this is getting it into position.

Plenty of big g-clamps and some box section to hold it in place, all went together within a mm each side.

[Sankey26]

All welded up:

[Sankey27]

[Sankey28]

Welds before cleaning up:

[Sankey29]

[Sankey30]

We have flitch plates to weld across the top and sides of these joints to reinforce them, they are not in place yet.

We're off to the local metal yard in the morning to see if we can pick up mor box section as the bit for the front hasn't arrived.

Peter




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Kev Admin

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Reply with quote  #2 
Peter

Another excellent visual project.

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Link to self build pictures 

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listerdiesel

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Reply with quote  #3 
Thanks, Ross, hopefully it will be a good unit when we've finished.

Peter



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listerdiesel

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Regarding weight balance/distribution, we've started the front extension today having picked up a decent bit of 100X50 at our local metal scrap yard, and in fact the rear has the longer extension at 750mm than the front with 600mm.

There will be an underslung LPG vapour tank and water tanks so we'll be able to balance it up by positioning those items.

Rain stopped play unfortunately, may get back up there later and carry on.







Just started raining as I took the pictures. More involved bracing needed at the front to strengthen the drawbar.

Peter


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listerdiesel

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Today's efforts.

We got the front A-frame re-connected, made up to two perimeter frames for the front floor and got the A-frame cross-beam welded in.

Going to temporarily rig up the lights and get it weighed in the morning.





















Peter

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listerdiesel

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Weighed it this morning, 380kg, that gives us just over a tonne to play with for the body and payload.

Peter




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listerdiesel

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Carrying on, we went over to Tinley Tech, who are fairly close to us, to see what they had in the way of LPG tanks to go under the floor.

We came away with a 35 litre tank, mounting frame, multivalve, piping and a level gauge kit.

Cooking etc needs a vapour outlet tank, what we bought is a liquid outlet tank, so we'll need to modify the pick-up tube and make a cap for it so it takes gas from the top of the cylinder and not liquid from the bottom.

The frame mounted up OK but we're not entirely convinced by it, it's only 2mm steel, although our mounting bar is 1/4" thick 1-1/2" angle and 50mm box with 3mm walls.

It looks OK, the gauge/multivalve is going to foul the frame to get it round to 30 Degrees below the horizontal, so a bit of thought there. The mounting frame normally goes t'other way up with the tank sitting on top.

We'll have another look at it today, it may be we'll rethink the frame and fit circular brackets instead.













Peter

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listerdiesel

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Today we are getting the body brackets welded on, then we can drill and bolt the aluminium extrusions onto them, giving us the floor and body support outriggers:









Philip got some undercoat over the bare metal, followed by a single coat of green, that will be finished off once all the body fixings are done.

The new brackets are 5mm steel and where possible they are welded over the frame joints to act as stiffeners.

Peter

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listerdiesel

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A bit breezy again today, but Philip carried on with the Sankey, took off the rusted metal sleeving for the lighting and put a new junction box on with black PVC sleeving.





Later we got the complete trailer up on its side so the welds could be finished off and some undercoat put on. A fairlt stiff breeze necessitated a temporary cover, so the old canvas tilt was pressed into action:





After that Philip got the undersides primed up.



The LPG filler was also fixed to the front drawbar:



Peter

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BurtSner

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Reply with quote  #10 
well this beats all the 'how do I change a bulb' threads, keep it coming [thumb]
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listerdiesel

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Next one will be: "Making a Motorcycle Trailer out of a Sankey Wide-Track trailer".  [biggrin][biggrin]

Peter

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listerdiesel

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Right, here are some update pictures, the lengths of body extrusion will be delivered today, cant rail, corner posts and side rave, plus a couple of corner capping castings.

Philip finished off the welding underneath by standing the trailer on its sides, then he painted the chassis:


The gas tank bracket has been reinforced and that is back on, plus it is piped up to the front filler point:


The body mountings are now fixed and the floor panel cut to size, wheelarch cutouts done. The floor is still loose in the shot, not located properlt yet:


A quick view under the floor to show what it is like the right way up. The gas filler pipe is visible coming forward to the filler:


A general shot of the floor panel, sun was a bit bright so not as good a picture as it might have been:


Another shot of the floor panel


Aalco's truck should be here this morning with the three lengths of extrusion, I'll post some pictures later.

Peter

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listerdiesel

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Aalco delivered just now:



That gives us the starting materials to get the body framework cut up.

Peter

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listerdiesel

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Reply with quote  #14 
Currently here:







Peter


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SANDBAGSID

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Reply with quote  #15 
Looking great peter, Lot of work well done and thanks for the update pics
makes it much more interesting when there is a few pics.[smile]

   Alan

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listerdiesel

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Lousy weather again!

Did get a dryish spell and got the front panel fixed in place.

Next step is to get the cant rails cut around the top of the front bevelled panels, then the roof can go on.

Peter


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SANDBAGSID

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Reply with quote  #17 
Its coming on well now peter, looking really tidy.

    Alan

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listerdiesel

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Reply with quote  #18 
Still raining!
 
Philip has got a 5ft flourescent and a 2-bar electric fire in there, and there's a decent sheet over the open top:
 
 
Door surround is on:
 
 
Door finished but waiting for hinges and lock etc:
 
 
Interior started:
 
 
Drier weather tomorrow.
 
Peter

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listerdiesel

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Reply with quote  #19 
The shower cubicle is done, the wall joint stiffeners need priming and painting and the panels sealed.

Doorway is cut and there will be a simple waterproof curtain across inside, probably a long/wide one to go around two sides.







Peter


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listerdiesel

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Reply with quote  #20 
We've got a bit more done, despite the weather:









The roof should be on today if all goes well and subject to the Sikaflex going off hard enough to handle.

Peter


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listerdiesel

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Reply with quote  #21 
After a long, cold day in the yard, we got the roof sheet cut out and fitted.

Work included getting the front bay area reinforced at the top, as there is not equivalent to the floor to stiiffen it, but it all got done, we finished about 17.30, my shoulders and legs were killing me!

Out in the road with the roof sheet unrolled, Rita looking on:





Looking up inside the front:


Working on the last few rivets:




View from above this morning:








It rained heavily last night and there are a few unsealed joints, but it should be pretty good now.

Solar panels to go up on there yet, so we are not finished with the stepladder!

Peter

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listerdiesel

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Reply with quote  #22 
Here's a few pictures from this morning, we turned the trailer round last night so we had better access to the side door.

Philip sealed up most of the corner joints etc last night so we should be pretty water-tight now.




Lots of work to get done inside, but at least it's dry and with a small heater, quite warm.

2 X 100W solar panels are going up on the roof, plus 2 X 110AH batteries and an MPPT solar controller.
 
Peter

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SANDBAGSID

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Reply with quote  #23 
It looks well on the way now, That s a good job you've done especially
with the dodgy weather we've had. Keep up the good work and nice
of you to keep posting the progress pics. Cheers peter.





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loopwithers

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This is what makes Britain great. [biggrin]
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listerdiesel

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Reply with quote  #25 
Work continues, but the near zero temperatures restrict what can be done.
 
Philip has been round the body and sealed up any gaps between the parts, Sikaflex 221 as usual, that has made it watertight now.
 
Hexagon headed bolts on the door hinges have been replaced with socket button flange types, nicer looking!
 
This week he has been getting the power inlet mounted for 240V, that gives him a safer means of getting power into the body.
 
The Truma water heater has been mounted up in position, it is a combined gas/240V unit so he has a variety of options when he is out with the trailer.
 
I'll get inside with the camera as soon as there is something to show.
 
Peter

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