#1

[ghcoe]

After drilling the wiring hole I then fed the wires through.

Feeding the wires

DSCF4376.JPG (158.14 KiB) Viewed 22903 times

Now I need to mark where the tail light studs will go. I do not plan on using nuts on the back side, but I do need to allow room for the studs since they are not removable.

Marking the holes

DSCF4379.JPG (151.99 KiB) Viewed 22903 times

Now I use a exacto knife to cut the holes in the canvas and deep enough into the foam for the studs. Then I can pick the foam out.

Cutting the holes

DSCF4381.JPG (144.98 KiB) Viewed 22903 times

[ghcoe]

Now for the final test fit.

Installed

DSCF4382.JPG (157.56 KiB) Viewed 22901 times

A couple of shots of the progress......

Nearly done

DSCF4365.JPG (159.38 KiB) Viewed 22901 times

Nearly done 2

DSCF4370.JPG (159.03 KiB) Viewed 22901 times

Hope for some more trailer time next weekend.

[KCStudly]

Looking really good. As always, you are doing fine work, and when I say fine, I don't just mean 'okay fine', I mean fine as in high grade or quality. Very nice.

[ghcoe]

Looking really good. As always, you are doing fine work, and when I say fine, I don't just mean 'okay fine', I mean fine as in high grade or quality. Very nice.

A compliment coming from the master himself. Thanks.

[GPW]

Well there ya’ go !!!

[ghcoe]

More progress on the trailer this weekend. I concentrated mostly on getting the hinge installed on the hatch. I found that with the hatch in position that it sat slightly higher than the roof of the trailer. I was already going to use a transition piece as a water diverter and as it turned out it was just the right thickness. I just had to install it under the hinge on one side rather than on top as intended.

Shim

DSCF4385.JPG (157.02 KiB) Viewed 22786 times

The hinges that I purchased did not have any holes predrilled so I was able to space the holes where I wanted them to be. After drilling the hinge I was able to use the hinge as a guide for the aluminum transition pieces. The transition pieces are intended to act as a water diverter to keep water from freely running into the hinge area. What water hits the hinge area should be easily taken care of by the sub roof gutter.

Gutters

DSCF4386.JPG (165.62 KiB) Viewed 22786 times

Gutters also keep light rain out of the sub roof gutter when the hatch is up. I am not sure if I will cover the hinge area with rubber or not. I guess I will see how this works first.

[ghcoe]

Here is a shot of the sub roof gutter with the hatch up.

Sub roof gutter

DSCF4391.JPG (141.78 KiB) Viewed 22777 times

Next it was time to come up with a prop rod method. I went down a purchased two small casters rated at 50lbs. I think that should be enough capacity.....

Caster

DSCF4393.JPG (151.38 KiB) Viewed 22777 times

Then I drilled out the axle pin.

Drilling

DSCF4394.JPG (156.74 KiB) Viewed 22777 times

[ghcoe]

Once I got the axle drilled out I had this........

Caster disassembled

DSCF4395.JPG (152.19 KiB) Viewed 22774 times

But, all I needed was this.

Ex-caster mounted

DSCF4396.JPG (146.58 KiB) Viewed 22774 times

Next, some conduit for prop rods. Turns out that one 10' piece was just the right length for two prop rods. How lucky is that

Drilling the prop rod

DSCF4397.JPG (154.66 KiB) Viewed 22771 times

[ghcoe]

But, of course no bolts the right length.... Not going to let that stop me now.

Prop rod installed with caster

DSCF4399.JPG (167.58 KiB) Viewed 22771 times

Then the test. Hatch deployed.....

Prop rods in use

DSCF4401.JPG (153.42 KiB) Viewed 22771 times

And of course they have to be stowed for travel.

Prop rods stowed

DSCF4402.JPG (155.49 KiB) Viewed 22771 times

Still have to make a lock in device on the hatch for the prop rods. That will have to wait till next week. If all goes well.

[KennethW]

{Lock devise for prop rods.}
I used a piece of PVC pipe with a wedge cut out so the prop rod snaps into the PVC pipe that is mounted on the inside of the hatch. But then I put the caster on the hatch so the rods swing down from the hatch and is stored on the inside of the hatch.

[GPW]

Is there some way to secure the prop rods at the top ... just in case the odd wind wants to blow the top around ...

[ghcoe]

Is there some way to secure the prop rods at the top ... just in case the odd wind wants to blow the top around ...

I am working on it. Not sure how yet though. I have a few ideas I am working on.

[loaderman]

Like the repurposed caster

[lthomas987]

Like the repurposed caster

Me too!

My solution is way less slick. I think I might be switching to this!

[ghcoe]

I felt comfortable enough to weight the trailer for a near final estimate. Loaded everything that still needs to be installed inside plus a little extra to compensate for paint weight. Was not as light as I was hoping, but did come in under expected. 480lbs overall weight, 65lbs tongue weight .

I still need to build a tongue box but that should easily come in under 20 lbs. So yes I am happy with the results. When I started to build I was thinking 500lbs was going to be tough to achieve. Once I started the build I was thinking 450lbs might be doable. At that time I was not even thinking of the addition of a tongue box though. With a tongue box and under 500lbs......YES!