Explorer Pod Build

Design & Construction of anything that's not a teardrop e.g. Grasshoppers or Sunspots

Postby dsmith » Mon Jun 15, 2009 9:15 am

I know what you mean about the next one, kind of like Lay's potatoe chips you can't stop with just one. As to the extension on the front I already have the trailer and no room for to add on. The good news is I have a nibble on the line for a potential buyer once it is complete, then it will be on to #2!! 8)
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Postby schaney » Sat Jun 20, 2009 9:55 am

Finished assembling and painting the frame.

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Here is how the shocks are setup.

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I'm tried of replacing damaged rear stabilizer jack so I made them removable on this trailer. The receiver tubes will also be used for a kayak rack.

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Postby stomperxj » Sat Jun 20, 2009 11:39 am

Nice looking frame :thumbsup: I like the removable stab jacks too... nice touch...
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Postby schaney » Sun Jun 21, 2009 8:38 am

Thanks, Durabak for doing the exterior should be here early next week.
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Postby schaney » Sat Jun 27, 2009 9:17 am

As I mentioned earlier I’m painting this trailer, light gray with black fenders, in Durabak, a polyurethane bed liner material. It comes in a textured with ground rubber in it and smooth that has an orange peel texture. The textured holds up well to things being kicked up by the tires. One thing I like about Durabak is the textured natural of its finish is good at covering up surface imperfections.

First I did the textured areas, this is the black areas in the first few pictures. Then went over everything with a couple of coats of smooth. This actual gives the trailer three different textures; the fenders/fender openings are the heaviest with only textured, the front/lower edge of the sides is textured with smooth over it and the remainder of the trailer is smooth.

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Postby schaney » Tue Jun 30, 2009 9:10 am

Got the trailer box mounted up on the frame and the fenders mounted.

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Postby schaney » Wed Jul 08, 2009 10:42 am

Here is the tailgate, I made it by gluing two pieces of 1/2" Baltic Birch together. I’m using a locking t-handle latch. The hinge on the left is the one I originally planned to use, but switched to the stainless steel “gate” hinge on the right due to clearance issues when opened. I’m also thinking about switching to a concealed piano hinge for a cleaner look and increased secure.

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Postby Endo » Wed Jul 08, 2009 3:27 pm

schaney wrote:Finally got all the suspension brackets and bushing pulled together, plan on welding up everything next week. Had to do some trimming on the front hangers so they’ll fit correctly.


Nice build!

Where did you order all of your suspension brackets?
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Postby schaney » Wed Jul 08, 2009 8:41 pm

Brad, The suspension brackets are from Ruff Stuff. For folks wanting a smooth riding suspension that are local to me, I'll shortly be keeping these parts in stock.
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Postby Endo » Wed Jul 08, 2009 8:57 pm

I figured it had to be from a 4x4/Jeep site. Thanks for the link.

What is the length of the leaf spring set-up (from hanger to shackle)??

Distance from frame to the bottom of the leaf spring?

At some point I want to upgrade the spring set-up on my current build. Maybe the set-up you are using would work for me as well.

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Postby stomperxj » Thu Jul 09, 2009 8:50 am

Wow, thats really lookin good schaney. Very clean :thumbsup:
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Postby schaney » Thu Jul 09, 2009 9:46 am

Endo, lenght is 45", with the axle on top of the springs, it's 4" from frame bottom to the top of the axle. There is +/- 1" depending on a 2K or 3.5K axle and which of the leafs in the pack you using. If I mix in OME extra leafs into the mix there is even more height/weight carrying adjustability.

Stomperxj, Thanks ... glad to hear your situation is improving and we'll see the Sawtooth finished this year.
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Postby Endo » Thu Jul 09, 2009 12:39 pm

Thank you for taking the time to measure the leaf spring dimensions.
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Postby schaney » Thu Jul 09, 2009 7:06 pm

Endo, no problem, here is some other dimension info about the spring pack that might be useful. The full pack with 6 leafs was 5 1/4" tall and compressed about a 1/2" per 175 lbs put on it. With only the first 3 leafs, they're 4" tall and compress about 3/4" per 175 lbs put on it. I'm initially running them with the first 3 leafs for a 1000-1100 GVW.
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Postby navigator » Tue Jul 14, 2009 2:23 pm

That's looking great!

I recall seeing a neat tent-topped trailer at Jeep Forums, a Conqueror Compact, with lots of accessible storage:

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The thread is here: http://www.jeepforum.com/forum/showthread.php?t=607948
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