Aluminum skin Benroy - 4x8 on a Harbor Freight!

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Aluminum skin Benroy - 4x8 on a Harbor Freight!

Postby Wildfire » Wed Aug 02, 2017 8:19 pm

Finishing this up in the next week or two...

Door is from Challenger. Window is a 2'x4' Hehr unit bought off ebay. Everyone's favorite harbor freight trailer. Maxxair fan.

Electrical uses a 360w 12v power supply to feed the LED puck lights and the fan, will likely add a 12v deep cycle battery at some point in the future. Also have 120v outlets plus USB and cigarette lighter outlets inside

Roof is 0.040, walls are 0.032 5052. Trim is a 0.5" x 1" x 0.125" unequal angle in 6063. R-6 foam in roof, no insulation in the walls.

Very basic build, no galley, all bed and interior storage bin in the back where the galley typically would be.
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Last edited by Wildfire on Sat Aug 12, 2017 7:57 pm, edited 1 time in total.
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Re: New aluminum build, 4x8

Postby greygoos » Fri Aug 04, 2017 9:08 am

Nice job. Good luck with your adventures.
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Re: New aluminum build, 4x8

Postby QueticoBill » Fri Aug 04, 2017 11:09 am

Nice! Is cabin removable? Looks like it could be is all. Did you home-anneal the trim angles?
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Re: New aluminum build, 4x8

Postby Wildfire » Fri Aug 04, 2017 12:23 pm

Thanks.

The cabin is held to the trailer with angle brackets and bolts from underneath through the 3/4" plywood floor. It could be removed (or moved to a better trailer) if wanted with a little effort. Underside is skinned too with 0.032" sheet.

The trim is 6063 and drilled every 8", it bent very easily with no heat required. Started at the front and bent it right around - used sheetrock screws to pierce the aluminum and draw it down tight. In the curves, it twisted a bit, but I whacked it with a mallet and it laid right down. After getting it formed and trimmed, we took it off, applied the sealant and then used the stainless screws to permanently install it. The trim was actually one of the easiest things to do.

If I did this again, I'd use less plywood and luan/weight and skin the whole thing with 0.032". The 0.040" on the roof is overkill. Did that because I thought the luan needed some extra support.
Last edited by Wildfire on Wed Aug 09, 2017 7:23 pm, edited 1 time in total.
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Re: New aluminum build, 4x8

Postby Wildfire » Wed Aug 09, 2017 6:10 pm

Just added 13" galvanized rims with 175/80D13 tires to the trailer. As-is, only have about 1/4" between the sidewall and bolt heads. Fixing that by swapping the bolts to hex head that will sit flush and installing 1/4" wheel spacers. Will end up with 3/4" or slightly less after those mods.

Have a set of 8x28x10 0.090" aluminum fenders coming. Found these from Nuera trailer parts for $63 shipped. Seemed to be the best price.
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Re: New aluminum build, 4x8

Postby flyguide » Wed Aug 09, 2017 6:36 pm

:thumbsup:
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Re: New aluminum build, 4x8

Postby Wildfire » Sat Aug 12, 2017 5:40 pm

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Mounted the fenders (28x8x10 0.090 aluminum) today. Much happier with the larger tires and prettier fenders. $200 all in for the tires, fenders and hardware - not bad.

The wheel spacers forced me to replace the studs, picked up the right ones at a local parts store.

Wheel studs for this HF trailer were Dorman 610-378.1 12mm-1.25 thread pitch x 14.35 knurl diameter x about 1.75" long
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Re: Aluminum skin Benroy - 4x8 on a Harbor Freight!

Postby Wildfire » Mon Aug 28, 2017 6:05 pm

Sewed the cushions up over the weekend. Followed a youtube video published by sailrite. I've never used a sewing machine for anything that ever mattered before. These turned out really nice. Very happy and surprised!

The monogrammed pillows were a close-out item at a store we happened to walk into. Perfect match for the cushions.
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Last edited by Wildfire on Sat Sep 09, 2017 8:55 am, edited 1 time in total.
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Re: Aluminum skin Benroy - 4x8 on a Harbor Freight!

Postby greygoos » Tue Aug 29, 2017 7:06 am

Very nice build, I wish you luck. Nice sewing job
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Re: Aluminum skin Benroy - 4x8 on a Harbor Freight!

Postby Wildfire » Tue Aug 29, 2017 7:02 pm

Weighed the trailer, came in at 755 lbs without any camping supplies or gear.

Should be well under 1000 lbs fully loaded.
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