The 4x4 Podcast Expedition Trailer build journal

[jeepin_idaho]

I interviewed Scott from Dinoot Trailers on my podcast a long time ago and ever since then, I haven't been able to stop thinking about building a trailer for my adventures. The biggest thing doing me though was the logistics of moving. Let me explain a bit. I drive a 99 Jeep Cherokee. My wife drives a 2007 Yukon XL. Since I'm in the Army, I frequently move across the country. To save money and travel more comfortably as a family with the 3 kids and a dog, we like to all ride in the Yukon and tow the XJ on a car hauler trailer. My 16' car hauler just wasn't big enough to hold the Jeep and an expedition trailer. In June I'll be moving for the 10th time in 10 years. But the difference is that this time we're heading to Alaska! The more important bit here is that the Army is paying to haul one vehicle for me. That means my XJ can take a commercial transport up to Alaska and I can haul an expedition trailer across the country and I'll the Alaskan highway!

I'm so excited that is finally my turn to start building a trailer! The first step was selling my car hauler. So I posted it up on Craigslist for the same price that I paid for it 7 years ago.

http://tapatalk.imageshack.com/v2/15/02/28/4abec73107c292a10a1ca9c7c74acb35.jpg

Within 24 hours of listing it, I had $1300 cash in my hands! Now on to the the new project.

http://tapatalk.imageshack.com/v2/15/02/28/ac1a02409ac8572cc4b0772b99042366.jpg

I bought their extreme duty 4x8 trailer frame and some other bits to get started. I'm ordering the Explorer Box plans from Compact Camping Concepts. The finer details of the plan aren't set yet but here's some of the things I'm thinking right now.

- I want to be able to remove the box and use the trailer to haul general cargo occasionally.
- I want to haul a family load of bicycles
- Needs too have a propane tank, fresh water tank, a spot for my chuck box, a cooler, on board battery for 12 volt stuff, and other camping kit of course
- I'm thinking about having the box fully enclosed for security and to keep to things from being abused too much on the gravel roads
- I will likely swap the able to a heavier one and the tires to match the Yukon size/bolt pattern
- I am also planning on adding a stick of 2x2 square running the length of the trailer for added strength

I'm looking forward to working on this and starting to use it. It's going to be a lot of fun and will of course be great content for The 4x4 Podcast.

Cheers!


Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

http://traffic.libsyn.com/the4x4podcast/Episode_28.mp3

[XJ Wheeler]

Sounds like a cool project with loads of potential.

Sent via messenger pigeon - i talk, he types.

[abebehrmann]

Project sounds awesome! Can't wait to see your progress. So is this being specifically built for the trip to AK, or will it eventually be primarily behind the XJ?

[autotech98]

Yeah id like to see it dan

[jeepin_idaho]

@abebehrmann, it will eventually end up behind the XJ occasionally.

I worked on it for a few hours today.

http://tapatalk.imageshack.com/v2/15/03/01/23283865751fa3d25e3c8a8ecd435b1b.jpg
http://tapatalk.imageshack.com/v2/15/03/01/633c59bf310d991e707a2e5128d2379e.jpg
http://tapatalk.imageshack.com/v2/15/03/01/fab8d45b64f7ce8b3d4c14e9050d8195.jpg
My 7yr old photographer caught some of the action.

http://tapatalk.imageshack.com/v2/15/03/01/213050f8799ea07df80662e5a0ef3ad2.jpg
Gotta make sure everything is square.

http://tapatalk.imageshack.com/v2/15/03/01/61064bd8f0b70607b959d8118981d958.jpg
And now it's a rolling trailer! This week I'll do the wiring and bring home the lumber to start building the box. And of course order some additional bits and components.

Progress!

Dan
http://the4x4podcast.com

[jeepin_idaho]

I worked on it for a few hours today.

http://tapatalk.imageshack.com/v2/15/03/01/23283865751fa3d25e3c8a8ecd435b1b.jpg
http://tapatalk.imageshack.com/v2/15/03/01/633c59bf310d991e707a2e5128d2379e.jpg
http://tapatalk.imageshack.com/v2/15/03/01/fab8d45b64f7ce8b3d4c14e9050d8195.jpg
My 7yr old photographer caught some of the action.

http://tapatalk.imageshack.com/v2/15/03/01/213050f8799ea07df80662e5a0ef3ad2.jpg
Gotta make sure everything is square.

http://tapatalk.imageshack.com/v2/15/03/01/61064bd8f0b70607b959d8118981d958.jpg
And now it's a rolling trailer! This week I'll do the wiring and bring home the lumber to start building the box. And of course order some additional bits and components. First thing to order is some different springs and a mount that involves a proper leaf spring setup with a shackle. I also need to replace the axle with a 3500lb one. And source some wheels to match the bolt pattern in my Yukon.

Progress!

Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

[prerunner1982]

10 times in 10 yrs..... no thanks. Like the project though.

[jeepin_idaho]

Sounds like a cool project with loads of potential.

Sent via messenger pigeon - i talk, he types.
Loads. I see what you did there ;)

[jeepin_idaho]

Project sounds awesome! Can't wait to see your progress. So is this being specifically built for the trip to AK, or will it eventually be primarily behind the XJ?
It will eventually be pulled by the XJ. But for this leg of the trip, I'll be running tires and wheels to match the Yukon XL that is pulling it.

Dan
http://the4x4podcast.com

[jeepin_idaho]

I worked on it for a few hours today.

http://tapatalk.imageshack.com/v2/15/03/01/23283865751fa3d25e3c8a8ecd435b1b.jpg
http://tapatalk.imageshack.com/v2/15/03/01/633c59bf310d991e707a2e5128d2379e.jpg
http://tapatalk.imageshack.com/v2/15/03/01/fab8d45b64f7ce8b3d4c14e9050d8195.jpg
My 7yr old photographer caught some of the action.

http://tapatalk.imageshack.com/v2/15/03/01/213050f8799ea07df80662e5a0ef3ad2.jpg
Gotta make sure everything is square.

http://tapatalk.imageshack.com/v2/15/03/01/61064bd8f0b70607b959d8118981d958.jpg
And now it's a rolling trailer! This week I'll do the wiring and bring home the lumber to start building the box. And of course order some additional bits and components. First thing to order is some different springs and a mount that involves a proper leaf spring setup with a shackle. I also need to replace the axle with a 3500lb one. And source some wheels to match the bolt pattern in my Yukon.

Progress!

Dan
http://the4x4podcast.com

[jeepin_idaho]

So I'm putting together the list of essential components. Here's my list so far but I feel like I'm overlooking some items.

Fresh water storage - 20 gallon minimum
Cooler or fridge
Deep cycle battery with ability to charge from vehicle while towing and shore power
Propane storage
Luggage storage
Chuck box does storage
LED camp lights
Shower/toilet tent
Hot water shower system
Gas can storage
Solar - I'm not sold on this yet because I'll be moving each day, therefore also charging, so is solar necessary? Maybe I can leave that for stage 2 once I get past the initial use expedition.

What am I missing?

Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

[bluedragon436]

With the wiring for the trailer did you do a 7 plug RV connector on the harness for the trailer?? Was just asking for as far as the charging of the battery while on the road part of your plan.. I would say especially while towing it across the country I wouldn't mess with the solar panels.. only cause they'd either be stored inside the trailer in which case not very useful.. or they'd be on the trailer charging the battery, but then taking the huge risk of something flying up and hitting them.. Is this a HF trailer you're using for the basis of your build??

[Carves]

I looked at doing something with one of those taiwan trailers a while back.

The ones sold down here must be gold plated or something .. :rolleyes:

http://www.carlex.com.au/index1.html?c44.html&1


Have a look through google images of aussie and sth african camper trailers.

Lots of them are just mobile bling wagons ... but you might find a coupla practical ideas you could use.



So I'm putting together the list of essential components. Here's my list so far but I feel like I'm overlooking some items.

Fresh water storage - 20 gallon minimum

A tank or jerries ?? ... I prefer jerries since its a lot easier to carry one of them down to waterhole compared to a whole trailer.

Cooler or fridge

Time away and meal preferences will dictate that one usually. I try to use a minimal amount of stuff that needs cooling e.g. powdered or UHT milk etc.,

... besides, if I want a 2" thick steak and a waldorf salad on the third day out ... I'll head for a restaraunt .. :D

Deep cycle battery with ability to charge from vehicle while towing and shore power
Propane storage
Luggage storage
Chuck box does storage
LED camp lights
Shower/toilet tent


Hot water shower system

On demand in car system ... or one of those black plastic shower bags ?? ... I carry a coupla 4gal stainless buckets to leave simmer alongside a fire for hot water. Handy for other things too.

Gas can storage

Solar - I'm not sold on this yet because I'll be moving each day, therefore also charging, so is solar necessary? Maybe I can leave that for stage 2 once I get past the initial use expedition.

Solar is all the rage down here .. personally, I think its just more junk to haul around ... unless one is camped somewhere for a few weeks - and cant survive without electricity when camping in the scrub.

What am I missing?

Probably another trailer load of stuff ... if your anything like me .. :D

[jeepin_idaho]

It is a HF frame. Solar is definitely out for stage one of the project. I've heard that the 7 pin connector is not sufficient to charge the battery if it'd really drained. So I've purchased the T-Max dual battery system. It comes with the isolator, the monitor, and some other bits. It has some intelligence to it so it knows when to charge and when to isolate. It also gives me the option to "self jump" in the event that my starting battery goes flat. That also gives me the flexibility to have a dual battery setup while exploring in my XJ and the trailer.

I also purchased the pieces for the hot water shower. That includes the Triton tankless water heater, a 12 volt pump, and a 20 gallon molded tank.

It was kind of an expensive trip to Amazon.com.

Dan
http://the4x4podcast.com

[4.3LXJ]

Dan, this is probably outside of what you are planning, but my son the plumber and I are planning hot water systems the use the exhaust from the Jeep to heat water. Not much to it, lots of flexible copper and an RV water pump.

[bluedragon436]

It is a HF frame. Solar is definitely out for stage one of the project. I've heard that the 7 pin connector is not sufficient to charge the battery if it'd really drained. So I've purchased the T-Max dual battery system. It comes with the isolator, the monitor, and some other bits. It has some intelligence to it so it knows when to charge and when to isolate. It also gives me the option to "self jump" in the event that my starting battery goes flat. That also gives me the flexibility to have a dual battery setup while exploring in my XJ and the trailer.

I also purchased the pieces for the hot water shower. That includes the Triton tankless water heater, a 12 volt pump, and a 20 gallon molded tank.

It was kind of an expensive trip to Amazon.com.

Dan
http://the4x4podcast.com

I've see the T-max system before.. Ran one on horse trailer, don't think it was wired up to do the "self jump" though... actually I know it wouldn't have started the Ram it was always hooked too.. lol.. What kind of connector are you looking to use to connect it to the Yukon, and ultimately the XJ?? Only asking cause I've been thinking about building up my own trailer based off of a HF trailer as well (one day).. if I don't end up picking up a pop up camper I've been looking at... and if I do, then I'll probably build a box on the front of it w/ a dual battery setup and would be looking to do something similar to the T-max setup anyways...

[jeepin_idaho]

The connection will be with 1/0 gauge wire and a big 200 amp rated Anderson Plug. You have to hit a button on the T-Max control module to manually put it into self jump mode...that's what I've read anyways. We'll know more one I get it in my hands.

I also picked up a steel fuel can that is non-CARB compliant. I plan on transferring fuel from the can to the vehicle using a siphon so I won't really have to work about using the spout anyways.

Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

[abebehrmann]

Sorta curious, what bolt pattern wheels come with the trailer?

[jeepin_idaho]

I looked at the T-Max unit last night and it has a button on the control module that asked you to put it into manually linked mode and charge or jump. I'm going to use 1/0 gauge wire to run from the battery at the front of the Yukon to the back. I have a 350 amp rated Anderson plug to connect power from the truck to the trailer. Also 2x 200 amp fuses along the connections. One will be close to the truck battery and one close to the trailer battery.

Last night I wired up the lights so now I'm legal to drive with the trailer. That will be helpful in picking up materials if I can find time this week.

http://tapatalk.imageshack.com/v2/15/03/10/5fe7f9a1060f013a3958fcc8479a257e.jpg

Also, I tried out a cordless soldering iron. It took a minute to warm up but then worked great to solder. And then the tip can be removed to melt the shrink tubing. If you think that you'll need to solder in the field, I'd recommend picking this up. Of course you could just twist and tape connections but since I'm looking at a long trip, I want to have the tools to properly fix something along the trip.

http://tapatalk.imageshack.com/v2/15/03/10/319bf41d7a8210bebbe6c2c7cc8cc1b6.jpg
http://tapatalk.imageshack.com/v2/15/03/10/570eb84e6fb2c27fdb0f55cb657c0574.jpg

And the first shipment from Amazon has arrived!
http://tapatalk.imageshack.com/v2/15/03/10/6b3a5221c98f369a6ec8394bc2fd971d.jpg

Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

[bluedragon436]

Looks like it is coming along nicely... That makes since with running the 1/0 gauge wire and Anderson plug.. That works out good for me, as I eventually wanted to wire up that setup anyways to use for jumper cables.. so I don't have to open the hood every time.. especially on my Ram

[XJ Wheeler]

http://tapatalk.imageshack.com/v2/15/03/10/570eb84e6fb2c27fdb0f55cb657c0574.jpg


Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

Must be pretty cold up there!!! :eek:

Sent via messenger pigeon - i talk, he types.

[nickyg]

Must be pretty cold up there!!! :eek:

Sent via messenger pigeon - i talk, he types.

What are you talking about?!? I see blue men all the time.

[jeepin_idaho]

I've been told I have ice in my veins. Maybe it's true.


Dan
http://the4x4podcast.com

[jeepin_idaho]

Today was a really big day in the trailer build. I didn't actually do any building, but I picked up a whole bunch of important pieces. I picked up the marine grade plywood from a real lumber yard, not a big box store. Marine grade plywood is usually not stocked at your average store. it's constructed with much better materials and a stronger more durable adhesive between the plies. I also picked up a piece of square tubing to run the length of the trailer to stiffen it up. I also picked up a set of used wheels that match the bolt pattern and size on the Yukon. The last stop before heading home was to the trailer shop. There I had one of the guys help me measure for the right width for the new axle. The new axle with the correct hubs and bearings should arrive in about 2 weeks. Tomorrow I'll make a trip to the regular big box store to pick up a couple boxes of screws a bucket of glue, and some less important pieces of wood for the assembly.

I expect to receive a replacement set of springs and a spring hanger bracket this weekend. And it's a good thing too! Because these this slipper springs are complete garbage! The maiden voyage with the trailer went well but I still avoided the highway because it was bouncing like crazy.

http://tapatalk.imageshack.com/v2/15/03/12/70d22dc2ca7572499b5a692e3ca08796.jpg

This weekend I expect to see some pretty serious progress on this trailer project.

http://tapatalk.imageshack.com/v2/15/03/12/8496a9b914d23e57b7d51e5c93b68c49.jpg
http://tapatalk.imageshack.com/v2/15/03/12/7cda389d970d3603f7ddd91df4ed82e9.jpg



Dan
http://the4x4podcast.com

[jeepin_idaho]

For some reason the internet or TapaTalk is eating my posts. All that work with my thumbs for nothing. I'll have a bunch of stuff to post later I guess.

stoooopid internet.

[Mudderoy]

For some reason the internet or TapaTalk is eating my posts. All that work with my thumbs for nothing. I'll have a bunch of stuff to post later I guess.

stoooopid internet.

This forum "Fabrication" is one of maybe two forums we have here that require MODERATOR approval. You'll notice that admins and moderators can see and reply to your posts here but no one else.

We're still working on the mods checking for posts waiting on approvals. Sorry it's not you, it's us. :D

[4.3LXJ]

I approved the thread as soon as I saw it. He should be able to post immediately as I understand it.

[Mudderoy]

I have moved this thread at Dan's request.

[jeepin_idaho]

Thanks guys. I've made some really good progress today so far. But I'm going to take a few hours off from the work to go meetup with some other podcasters and social media types in the area for dinner. Then back to work for a few hours. Nothing has been glued and screwed yet but I've made a lot of saw dust! Pics to come tonight.

Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

[cpttuna]

Good luck with the build and THANK YOU for your service to our country

[Carves]

I expect to receive a replacement set of springs and a spring hanger bracket this weekend. And it's a good thing too! Because these this slipper springs are complete garbage! The maiden voyage with the trailer went well but I still avoided the highway because it was bouncing like crazy.


Good move on a shackle setup.

I'll bet Im going to regret, getting slippers on the latest trailer - even tho it wont do much more, than cart a bit of garden waste to the dump.

[rabies]

seeign that these trailers are budget friendly. curious to see what this one turns into

[jeepin_idaho]

This weekend I spent quite a bit of time working the trailer but I also had more interruptions than I had expected. The first job was to attach the base board. I want to be able to remove the box on occasion and be left with basically a flat bed trailer.*

http://tapatalk.imageshack.com/v2/15/03/18/7315a3b329a56fe2b3d96bc2be0fca7f.jpg

http://tapatalk.imageshack.com/v2/15/03/18/dce54e4edb65af592dbc51bed16c24cc.jpg

First thing was to clearance the wood around the trailer frame bolts do that the board sits completely flat against the frame. I simply marked or the areas and ran a router around those sections. Then I lined up the board and marked and drilled holes in the 3/4" board that lined up with existing holes in the trailer frame. I then used T-Nuts on the top of the board and ran 3/8" bolts up from the bottom. The result was a board mounted to the trailer and the surface is completely devoid of bolt heads or nuts. I love using t-nuts for that reason.


With the trailer bed taken care of it was time start tackling the box. I laid out my gear on the trailer and built in some extra room in each compartment to leave some room for possible gear upgrades in the future. After I had my wife look at it and try to sharp shoot my design (I asked her to do that to help force me to think through the whole thing) I was ready to start cutting. The plans look like they call for 2x2s as corner blocks.* All the 2x2s at the big box lumber yard were complete crap. So instead I decided to pick up a bunch of 2x4s and rip them in half on the table saw. The results were 10x better than buying them pre cut and cheaper in the end. The next step was to glue and screw the 2x2 corner blocks to the box base.

http://tapatalk.imageshack.com/v2/15/03/18/51cb97755f4afaab69d97e8bfa692cef.jpg

I ran enough glue to create just a bit of how squeeze out when screwed down tight. I put a couple screws in from the top to hold the corner blocks in place while I flip over the plywood. By screwing the plywood to the corner blocks from the plywood side, the screw catches each layer of the plywood creating a much better bond. I also buried each screw head about 1/8" below the surface so that I can go back later and use wood filler and completely hide the screws. I used more screws than I had expected but I trust the experience of others who have built similar projects. There are screws every 3-4 inches. I also used Tite Bond III glue which is great stuff. With all those screws, there was no need to use clamps.


I then flipped the bottom back over and started laying out the compartment dividers and the front panel. I decided to use full width 2x4s for the side pieces so that there would be some substantial material connecting the come blocks. This should also add a lot of rigidity to the box, but may be overkill for someone that doesn't plan on carrying a load on top of their box. I related the process of glue and screw for 2 panels but tab of of time for this weekend.

http://tapatalk.imageshack.com/v2/15/03/18/89fa9c146b0c5ccd075d37cf1fbbab8b.jpg
I'm out of town this week so I'm not getting any work done on the trailer unfortunately. But I think the progress will be steady once I get back to it. I'll need to buy a lot more glue and a couple more boxes of screws.*

Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

[jeepin_idaho]

It's been a bit since the last update and no work has been completed. But some more stuff has arrived.

http://tapatalk.imageshack.com/v2/15/03/24/843e321ec25fa083b2a8e9de20f6c66f.jpghttp://tapatalk.imageshack.com/v2/15/03/24/c9f07f79aa686c75f69640247a6b4bbc.jpg

Here we have the replacement springs and hanger brackets. This replaces the crappy slipper springs that came with the harbor freight frame. These are softer but heavier duty and uses a proper shackle setup. I need to get them primed and painted before I install them.

While I'm at the painting I need to shoot the wheels with a fresh coat of paint. And if better do that soon because the axle and tires will be ready for install soon too.

http://tapatalk.imageshack.com/v2/15/03/24/b688ddedc016362b84451ff17bc87630.jpg
Also last week I paid a visit to Lodge Manufacturing headquarters at South Pittsburgh, TN. Lodge hooked me up with one of their new seasoned steel skillets and a slotted steel griddle. These pieces will be perfect for the camp cook set. The seasoned steel is lighter weight than cast iron but is cared for the same way.

http://tapatalk.imageshack.com/v2/15/03/24/81aea3e1e1fb956b117902572b98c591.jpghttp://tapatalk.imageshack.com/v2/15/03/24/10c3833033ec42cfae25e56403bccadd.jpghttp://tapatalk.imageshack.com/v2/15/03/24/71de24ae6376691ad1ce83c9ddbd1da3.jpg
I also added another dutch oven to my kit because it's nice to be able to have dessert cooking at the same time as dinner so they are both ready to be enjoyed.

Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

[Mudderoy]

Living Lodge!

[bluedragon436]

I've got a few Lodge items, and love them... but mine are cast iron, and haven't left the kitchen... lol.. Might have to look into new seasoned steel items... especially since they can be used over a fire just the same as the cast iron pieces "of old"...

[jeepin_idaho]

I've got a few Lodge items, and love them... but mine are cast iron, and haven't left the kitchen... lol.. Might have to look into new seasoned steel items... especially since they can be used over a fire just the same as the cast iron pieces "of old"...

Oh I have a large collection of cast iron pieces that are used at home and on the trail. Typically, I'll only take a 12" skillet and dutch oven on the trail because I can make basically any meal I want with those two pieces of kit. The seasoned steel will be added to what I already have because this trip may have some additional requirements since it will be about a month long trip. And once we get to the other side, we'll likely have a bit of a wait in the new house in Alaska before the full array of kitchen stuff arrives. Fortuanately my camp kitchen is more than capable of accomplishing daily needs even at home. I could probably downsize all the home kitchen stuff but then that would mean that my camp kitchen has to be repacked each time I want to go out on an adventure - no bueno!

[jeepin_idaho]

I've been making progress on the box construction but it's been slow since I haven't had a lot of time to commit to it. School has kept me really busy the last few days/weeks. At least I'm getting some help from my family! I may need to buy another orbital sander so that I can put more people to work at once.

http://tapatalk.imageshack.com/v2/15/03/31/36775e43597058ed0cc481432b19a074.jpg

I also tried out the Triton camp shower using a garden hose. It worked great but the real test will be how it performs with the 3gpm pump running. It sure will be nice to have a hot shower at camp!

Triton 5L Camp Shower Initial Review: http://youtu.be/PNPL0gZJQ_s

I used the shower to clean up my trailer wheels for paint. I shot the wheels with primer before painting them. I still need to get some clear coat on the wheels but they look great! Hopefully soon I'll be able to pick up my 3500 lb axle and his to match the wheels. It's due in any day now.

http://tapatalk.imageshack.com/v2/15/03/31/171754a7f030353b2d37b8f5a85d2878.jpg

[jeepin_idaho]

I'm long overdue for an update on this project. *Life has kept my pretty busy so whenever I wasn't tied down to school/work/family stuff I've been slowly making progress on the trailer. *I've been posting a bunch of picture over on my instagram (https://instagram.com/the4x4podcast/) so here's some of the details of what has been done since I last posted here.

http://images.tapatalk-cdn.com/15/05/01/fb9eeed3a75c6bac618800b69cb7e4dc.jpg
http://images.tapatalk-cdn.com/15/05/01/807bb9e64590ccd14424b9ae8b6e00dd.jpg
http://images.tapatalk-cdn.com/15/05/01/74e0b8582e6842eea03664be182d55e0.jpg
I built all the doors and built a frame for each door to help give them some stability. *I also countersunk the hinges and mounted the doors. *Of course, after I got the doors hung I realized that I'm going to have to pull them off for final paint and then the gaps around the doors will be different. *So I know I'm going to have to trim them down again before I install the door seals. *
http://images.tapatalk-cdn.com/15/05/01/d9bfcc1e738a138f9776ed9b89382c72.jpg
http://images.tapatalk-cdn.com/15/05/01/9be491fe761db2fd55ef72476608385c.jpg
http://images.tapatalk-cdn.com/15/05/01/c5122c2da0aef987efe58a984e6900c7.jpg

I built a bracket that hangs down from the top (will also serve as additional ribs to provide stability/strength to the box) that will hold the camp table that I also built. *This will allow me to open up the back door and still be able to access the table despite having a pile of duffel *bags and such in the cargo area. **
http://images.tapatalk-cdn.com/15/05/01/17ed099a63e03f07db83f42b9768e5d8.jpg

I also managed to get the roof panel installed so now the box looks pretty complete. *I also added a shelf in the second compartment so that I have a spot to store the dutch ovens and camp shower while in transit. *
http://images.tapatalk-cdn.com/15/05/01/334e200cdabb49eb8c1944bdb6d6096e.jpg
http://images.tapatalk-cdn.com/15/05/01/64a17edb33ee698305cb6af9708dc413.jpg


Dan
http://the4x4podcast.com

[Mudderoy]

How'd you make those slots for the screws to hold the frame together? Looks like it was done with a jig.

[jeepin_idaho]

How'd you make those slots for the screws to hold the frame together? Looks like it was done with a jig.
It was a jig. It's a pocket hole jig. The thing creates a really strong joint when you also use a quality glue.

Dan
http://the4x4podcast.com

[bluedragon436]

It was a jig. It's a pocket hole jig. The thing creates a really strong joint when you also use a quality glue.

Dan
http://the4x4podcast.com

Did you use the Keg tools pocket hole jig?? Been looking at picking up a few of their products... as I've been thinning about getting into wood working a bit..

[jeepin_idaho]

No. I used the harbor freight version because it works the same and was a fraction of the price. I've had it for a couple years and still works like a charm. I did have to replace the drill bit but that wasn't very expensive.

Dan
http://the4x4podcast.com

[bluedragon436]

No. I used the harbor freight version because it works the same and was a fraction of the price. I've had it for a couple years and still works like a charm. I did have to replace the drill bit but that wasn't very expensive.

Dan
http://the4x4podcast.com

I'll have to look into that.. Wouldn't mind saving a couple bucks... especially on something like that.. always thought the Keg ones were a bit expensive... that's why I don't own one yet...

[nickyg]

Good call on adding a child stowage compartment.

[jeepin_idaho]

This week there will be a lot of progress made since I have officially completed grad school and I have a few days off from work.
http://images.tapatalk-cdn.com/15/05/09/a05e5c813996d7a335589c5b64e9068f.jpg

The painting is complete and it's time for final assembly of major components. Once that's done I'll take it out for a test drive to the weigh station to get an idea of the dry weight.

http://images.tapatalk-cdn.com/15/05/09/bd523a09974996967b14b995322f4c25.jpg
http://images.tapatalk-cdn.com/15/05/09/5ed073111f4ee8a3707057ff74c5a258.jpg
http://images.tapatalk-cdn.com/15/05/09/1b9f175138ca9f7781ac3f81c3f4aaee.jpg

Dan
http://the4x4podcast.com

[4.3LXJ]

Grad school eh? What are you going to be when you grow up? :D

[jeepin_idaho]

Grad school eh? What are you going to be when you grow up? :D
I'd like to be a professional bum when I grow up but to make that happen I'm going to have to make some good money while I still have the inclination to actually show up to work.

Dan
http://the4x4podcast.com

[jeepin_idaho]

I didn't get as much done as I would have liked because I got tied up running errands with my family for the upcoming trip through Canada to Alaska. Maybe I'll be able to get some more progress made later tonight though.
#BabyPassport
http://images.tapatalk-cdn.com/15/05/12/c2fe14c58d36eea862e67f12073e409c.jpg

I did get a bit done though. All the doors are hung and the lock/latches fastened.

http://images.tapatalk-cdn.com/15/05/12/135a60c4ba76029a74d2ef8dcac001f8.jpg

I also have the main trailer board fully mounted to the frame. It's actually bolted on in 15 locations...probably more than necessary but of 10 spots is good then 15 must be better, right?! Tonight, I'd like to get the trailer rolled back underneath the box and set in place so that I can have some of the garage space back.

Dan
http://the4x4podcast.com

[jeepin_idaho]

Bam! The box is (mostly) on the trailer! Now that's progress! I need to pick up a couple handles to help lift and maneuver the box into place since there is no way to get your fingers under the box once you set it down. But that can wait. There is plumbing, electric, and lights to work on till I can make it to the big box store.

https://vimeo.com/127677310

Dan
http://the4x4podcast.com

[jeepin_idaho]

Well I'm sitting in line so I figured I'd post an update. I'll have to back up a bit and give the background and fill in the details that I missed before.

I bought a couple pieces of flat bar stock and bent them into some straps to hold the water tank in place. I used 2" vinyl hose to connect the outside filler door to the tank. The bends in the hose were a bit more sharp than I liked so I added a pair of 45° angle elbow joints to smooth out the bends. I then sealed the joints with some glue and the self-vulcanizing tape to prevent leaks. The water tank was then connected to a short run of hose to a strainer, then to the 3gpm Shureflow electric pump, and finally to the filler door. I ran the wires for the pump switch to the filler door as well so when I want to use the water I simply open the door and flip the switch. The one lesson learned is that I need to also install a vent tube so that as water fills the tank, the air inside the tank has a place to go. As I have it now I get a geyser out of the fill tube once the filler neck is full. I should have thought of that before but oh well, I'll slow down when filling the tank till I have the vent hose added.

https://instagram.com/p/3WolmSpuRx/

The battery did a great job running the fridge, lights and pump for 2 days which is a great sign.
http://images.tapatalk-cdn.com/15/06/09/5364482fd5f673294d5220798de42e8b.jpg

The fridge is AMAZING! its super quiet and power efficient. The insulation is so good that the compressor doesn't have to run very often to keep the frozen stuff frozen below the thermal barrier and the refrigerated food just cold. FridgeFreeze is the way to go.

http://images.tapatalk-cdn.com/15/06/09/74a697321fc846187ee83a4082c2b2d7.jpg

The whole time my plan has been to ship my Jeep Cherokee XJ and pull the trailer with the Yukon XL. Turns out that the shipping company won't accept my XJ because it does not have a mechanical parking brake. That curve ball is a big story all in itself that I'll save to tell on The 4x4 Podcast. Ultimately the decision was made to ship the Yukon and drive the XJ....on 35" mud tires...and 8" lift...with 5 people and a dog. Ugh. That also meant that I had to get the tent moved over from the Yukon to a trailer that didn't have a rack. I sent out a message to a local fabrication shop in Kansas City, Major Metal Fab for some help. I dropped the trailer off at his shop on Saturday night and by Sunday the rack was painted, mounted and ready for the tent.
http://images.tapatalk-cdn.com/15/06/09/9568e1104716b4c2ce9d05635fd2c014.jpg

http://images.tapatalk-cdn.com/15/06/09/acc4dd417428f03eaf9284db501e474e.jpg

And that's where I am currently. Here's what's left on the punch list for the trip
- I need to fix an issue with the trailer light harness on the Jeep
- Get AC fixed
- exterior flood lights for around camp
- fab/mount fenders
- add water tank vent tube
- fab fuel can rack holder for Jeep roof rack
- Move Yukon spare tire to Jeep rack for trailer spare
- stencil The 4x4 Podcast logo on trailer

I think that's it for now. I can't wait to get this show on the road and Alaska bound!

Dan

Sent from my SM-G900V using Tapatalk

[4.3LXJ]

No mechanical ebrake, that draws vacuum. Not that you really need one. Well, the trip can be done. Have you thought about a pet carrier for the dog?

[jeepin_idaho]

Already have a kennel. Humphrey is a good traveler.

Sent from my SM-G900V using Tapatalk

[4.3LXJ]

We used to put our dogs in cages when traveling. Much easier than a hot dog panting and drooling in the back seat. Had that happen with a spoiled dog out on the rocks a couple of years ago. No fun for me. AC was broke that day too

[Mudderoy]

Already have a kennel. Humphrey is a good traveler.

Sent from my SM-G900V using Tapatalk

Every dog has their day and Humphrey's is Wednesday! :smiley-taunt002:

[jeepin_idaho]

The trip is in progress!http://images.tapatalk-cdn.com/15/06/16/9d2810495eb2127a3b1cc0876cc8ecb9.jpg
http://images.tapatalk-cdn.com/15/06/16/4ae8617d164d5496595b17b0129252c5.jpg

[Mudderoy]

The trip is in progress!http://images.tapatalk-cdn.com/15/06/16/9d2810495eb2127a3b1cc0876cc8ecb9.jpg
http://images.tapatalk-cdn.com/15/06/16/4ae8617d164d5496595b17b0129252c5.jpg

How does it sleep? Is the A/C in the window on the other side? Have you yelled at any of the kids yet? lol

[XJ Wheeler]

ARE WE THERE YET?!

Sent via messenger pigeon. I talk, he types.

[jeepin_idaho]

Actually we got the ac fixed. There's a slow leak on the high side - the Schrader valve is the culprit. The shop said that it will probably hold a charge for a few weeks and then need to be recharged. I told them that in a few weeks I won't need ac anymore.

The question "are we there yet" requires a calendar to answer.

Dan
Typos courtesy of Tapatalk
http://the4x4podcast.com

[4.3LXJ]

Dan, you can buy valve caps with O rings in them. They will seal it as good as a valve. If you have the R134A adapters on, pull it off and use the regular valve cap. Then you can avoid the constant recharge

I am interested in the tent and how it works out. Eventually I want one for the top of the XJ

[Carves]

............I am interested in the tent and how it works out. Eventually I want one for the top of the XJ


On the trailer is the best way imho.

On the car is a PITA ... if you need the vehicle to explore away from the campsite.

[jeepin_idaho]

On the trailer is the best way imho.

On the car is a PITA ... if you need the vehicle to explore away from the campsite.
If agree with that. I'll give more info on the tent when I've got time to type

Sent from my SM-G900V using Tapatalk

[4.3LXJ]

Well, here is the thing with us. I have a great tent. It takes a 40 mph wind and doesn't budge an inch. But it takes 30 minutes to set up and with all the rest of our camp stuff for a base camp, it takes about 2 hrs to set up and tear down. So we don't camp unless we are staying at least two nights. I was looking for a way to camp overnight with quick set up, say if I went up the Rubicon or any other overnight trail that would give the little woman the comforts. Me, I can sleep under the stars