Custom Off Road Camp Trailer

Brucker · Nov 9, 2023

***Disclaimer: This project was completed earlier this year and is currently out being used and loved by the owners.***

Recently, I was tasked to design and build a few parts for a custom camp trailer being built off of a late 40's/early 50's era Bantam TC3 utility trailer. These parts are to include a water resistant, self lifting, lockable roof/lid (yes, the tailgate will still open without having to open the top), a custom scissor lift assembly for a rooftop tent (Tuff Stuff RTT with annex room), as well as reinforce the main structure of the trailer (yes, an exo cage on a trailer) to handle the additional weight. Also fix an issue with the aftermarket hitch (Lock N Roll), and lengthen the factory support leg to compensate for the height difference after the client did an axle flip and larger tires.

Trailer and RTT were brought into the shop. The RTT was then put on a shelf till it's needed. The trailer was inspected and a game plan was formed.

Brucker · Nov 9, 2023

First order of business was to lengthen the factory support leg. Client wanted to keep the factory components and looks as much as possible. So we designed and built a simple extension bracket that offered just that.

Existing support leg, just a tad short:

Removed:

New extension:

Reassembled:

Brucker · Nov 9, 2023

Got started on the water resistant top by building a simple frame out of 3/4" square tubing.

Brucker · Nov 9, 2023

With the main framework welded up, I added some 1.5" channel along the front edge and sides to create a sturdy lip and some eye appeal to the structure. The rear gets left alone so the tailgate is able to open and close without lifting the top.

Test fitting:

Brucker · Nov 9, 2023

Skinning the top is always a long process. Heat from welding will easily warp the structure if not done correctly. I cut a sheet of 16ga to the exact measurements needed. Then start the tedious process of welding it up solid.

With the welding complete, everything gets sanded smooth. Amazing how much metal dust one can create in a short amount of time

Now that the top is all cleaned up, I use the shop built rolling gantry crane to help with the heavy lifting. Test fit of the top and everything is aligned perfectly. And the top is still as straight as an arrow.

Brucker · Nov 12, 2023

The Lock N Roll hitch that was installed at some point, was done so poorly. It was welded in at an angle and wasn't square to the trailer. So I dismantled the welded and bolted together assembly and cleaned everything off of the actual hitch. I will rebuild this structure correctly at a later date. I then removed the front toolbox so I could properly align the frame rails again.

Brucker · Nov 13, 2023

I am designing and building this as I go. Client dropped off the trailer and tent, told me what he wanted as a final outcome, and is leaving the rest up to me. Because of this, I haven't ordered in all the necessary parts as I still am unsure of exactly what I will need. So I decided to jump into designing and building the scissor lift assembly so I can figure out some of what's needed and get it ordered.

Decided to build a simple rectangular upper frame that the tent will mount to. And that the rest of the scissor assembly will be attached to. A center bar will be needed for the jack that will be used for the actual lifting. The client wants a manually operated jack so that the setup will work anywhere, anytime, without power or access to tools. I tried to convince them that a liner actuator and a deep cycle battery charged when hooked to the vehicle and even possibly some solar panels. But that was a no go. They really liked the idea of using a scissor style automotive jack, so I figured out some heights and ordered one in. You'll notice the crank will accept a 19mm socket. This will allow me to make this semi-powered by using an electric impact. Then the client could do the same if they so desire, or they can crank on it by hand.

I figured out the size of top framework, then cut the needed pieces and welded them together. As with everything on this build, I want this assembly to be fairly lightweight but it still need to be sturdy and durable. This needs to support an RTT along with 2-3 people and possibly a dog or two in the tent.

And just to appease my own curiosity, I set up the frame on the jack to get a better sense of what the next steps I should take will be.

Brucker · Nov 16, 2023

Each corner of the lift will need to be supported in order to achieve the correct weight distribution throughout the entire travel of the scissor assembly. I decided to go with a collapsing X for each corner. The outside top and bottom would be bolted into place and the inner top and bottom would be the slides with the lower being able to be pinned into multiple different locations. The slides and other bushings would be made out of delrin as to keep moving parts to a minimum. And as well to keep the noise and rattles away. Took a few measurements and started cutting most of the small parts needed to make up the different X assemblies.

Then the machine work came for the parts that needed it:

Test fit a few pieces:

Brucker · Nov 16, 2023

With the pieces cut and fitting well together, I welded the assemblies together.

Then assembled the X's

Brucker · Nov 16, 2023

Having the X assemblies built, I could weld them onto the upper frame I had previously made.

simps80 · Nov 17, 2023

Sheesh

Brucker · Nov 17, 2023

Got started on the lower tracks. These will be welded to the new top of the trailer and become the lower part of the scissor assembly. Cut some angle iron, drilled the necessary holes, the spaced them correctly on the fab table to start tack welding the assembly together. Then cut the rest of the pieces needed and added them in. Once all were tacked together, everything was welded up solid. I left the corners of the ends open so they would trap in any dirt or other debris.

Brucker · Nov 17, 2023

Placed the tracks on the fab table and inserted the upper framework.

Then I had to give the assembly a try to see if my design worked as I planned.

Brucker · Nov 20, 2023

More small part work. This time the bolt on tops for the upper slides. And the backets I already made get drilled and tapped. These will also get some delrin for easy movement.

Then tack welded the jack mounts into position.

Brucker · Nov 21, 2023

Parts are trickling in and the lower springs finally arrived. These will help keep a constant pressure against the lower slides which will help the slides travel at the same pace since the tent is not perfectly weight balanced at each corner from the factory. I cut some small tabs to use as mounts for the springs. Then welded them into position and attached the springs.

Brucker · Nov 21, 2023

Separated the upper frame from the rest of the assembly. This gets final welded after some mounts for the tent get added to it. I also clearance the lower frame rails for some of the hardware so I could get the assembly to sit as low as possible when collapsed.

Brucker · Nov 21, 2023

With the majority of work being completed with the lift (pretty much just waiting on the upper springs) I shift my focus to the trailer itself. It is an older light weight unit. It was designed to contain items within it's walls, not really on top of them. And even though the top will distribute the weight across the front and both sides. The top still will open to one side putting all the weight onto only one side. And those sides are just sheet metal. So the whole thing needs to be re-enforced. Decided to do just that by creating an exo cage of sorts. I came to this decision because of a few reasons. One, I want to keep as much space available inside the trailer. Another is that I just so happened to build an exo on a Jeep XJ a few years back for the same client. I know he wants the color scheme to match the XJ so why not match the styling as well?

Here is a look at the trailer before any tubework is added.

Decided to start at the top and work my way down to the frame. Took some measurements and cut some pieces to wrap around the top perimeter just under the rolled edge. Then clamped them into position.

Then mark out where I need to make a notch at the rear for the stock tailgate chains. These holes will also be used to lock the tailgate with padlocks. Once marked the sides get cut, welded, and sanded smooth. Then get clamped back into position.

Brucker · Nov 21, 2023

Got to work on the front down bars. Took some measurements and the cut and notched the tubes so they would fit nice and tight.

And you can see that this exo will not add any overall width/length to the trailer as it is flush with the rolled top edge.

Then got to work on the side down bars

Brucker · Nov 21, 2023

With the exo tacked together, it got removed in sections to get fully welded and sanded smooth. The front section:

And then the sides:

Brucker · Nov 21, 2023

Trailer and exo get prepped for welding. Really tried to keep the prep for the weld area on the trailer to a minimum for maximum protection from rust. And the backside of the exo gets coated in weld thru primer.