Trailer rebuild

Huntindave McCann

Huntindave McCann

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I've been considering doing this for about a year now and after getting back from Lacrosse I said it was time.

I have grown weary of busting lights when backing into ice at the ramps. That and I am always forgetting to plug the lights back in for the return trip home. This time I busted the lens backing into my drive when I misjudged how close I was to the tongue of my other trailer. So,,,,,,,,, it was time for some modifications to my trailer.

This is what I started with;

IMG-start.jpg



First thing was to dismantle the trailer down to the bare frame section;

IMGP-bareframe.jpg



An abrasive blade in my grinder, made quick work of cutting out the center section of the rear cross-member. No turning back now;

IMG-firstcut.jpg



Next I cleaned up the cuts, clamped the cross-member back in place and welded it back in. Only now it is 3.125 inches lower to the ground. Also added 4 gussets to strengthen the joints.

IMG-gussetweld.jpg



Next up is the task of raising the lights. Naturally they will require some sort of upright to be mounted to. I cut extensions for the cross member, notched then for the upright. Then did the same for bracing running back to the frame. Once it was all fitted and tacked in place, I welded it off complete.

IMG-readyforpaint.jpg


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Now I need to run to town to pick up some paint. Then it will be time to reassemble and install new LED lights. As I was rebuilding, I drilled holes where needed in all the pieces, such that the wiring will be entirely enclosed within the frame.
 
Nice work Dave, I like the drop center on the rear crossmember. LEDs are worth it every way. Must be nice to have all the time in the world to do these projects.;^)
 
Dave,

Really looks great!!

Just a tip from someone who's redone many a trailer. If you're going to store the trailer outside, make a "chase" to run the wires through, as mice WILL get in the channel if there are any openings, and chew on the plastic insulation. I don't now why, but the LOVE plastic and also spun fiberglass to make nesting material.

I redid a duckboat trailer many years ago, and stored it outside, when I went to use it in the fall, I kept blowing tail-light fuses in my old truck. They only blew when the trailer was on the vehicle. I couldn't figure out why, as I installed a new wiring harness when I redid the trailer. I disconnected the lights and pulled the harness out. The insulation was chewed off almost the entire length of the harness that was INSIDE the trailer frame channel. I replaced it, and routed the wire outside of the frame, inside of a 1/2 pvc pipe, that I attached to the frame.

Stones and gravel will not really damage the exposed wiring, and any damage can the seen and repaired. When it's buried inside of the frame, you'll have NO idea where the problem is, when a short occurs.

Just a thought.

Again, SUPER JOB!!!

Art
 
Tom,

You would be proud of me,,,,, I did NOT use my CNC machine at work to cut all the angles and radii needed. I free handed it all with my grinder in my driveway!
 
Art,

I understand what you are saying about the wiring. The original run was inside the frame except where it exited to connect to the tail lights. I am essentially extending the system to reach the new mounting position of the LED lights. I drilled holes in all the new frame pieces so that the wires will continue to be enclosed. My experience with the wiring is that any exposed loops will eventually get caught on something. The wires will receive added protection where ever they cross joints in the frame tubing. I've deburred all the openings but a flex sleeve over the actual wires will give additional insurance against rubbing and chafing. Your method of using pvc conduit is a valid method and may be better protection from mice.

I plan to make up my own wiring harness. All the drops will be crimped and sealed, then heat shrunk on top of that. Dedicated ground wire for each light. I've installed trailer wiring for about 46 years now both as a professional and hobbyist and I hate working on lights in the middle of the night during a pouring rainstorm. Especially if it involves a horse trailer still full of horses. Wiring on that one was simply stapled to the bottom of the floor boards. Floor boards now dripping with rain water and horse shxt. Didn't have any wire to run new so had to try and fix what was there.

I've had rodents chew the wiring on my motorcycle in the garage over the winter. Luckily it only involved the horn wires and was an easy fix.
 
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Dave, you are going to be happy that you have your lights on posts. I have always had those on my trailer, you really have to try hard to break the lights, and it makes it soooo much easier backing up.
 
Dave,

Looking good on the trailer. I put my lights high like you're doing and really light them like that. I also got a pair of guide lights for the top of the guide post. nice in the morning backing the trailer in.

http://www.amazon.com/...-Light/dp/B0035D7TUI

Kyle and I have been looking a light duty welders here lately. What brand are you using? Is it stick or mig?
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I think it would be cool to wire some post lights like you show here Ed into the reverse lights on the vehicle. That way they only come on when you are backing up. Maybe a couple of small dim LED's shining forward so as to not wreck your vision but allow you to see where the trailer is.

You ever get the pic'sent you over the weekend?

Mark W
 
Looks great Dave. I think you will really like the LED lights. I finally got tired of always having a bulb burned out last year and rewired my whole trailer with LED lights, individual grounds and sealed connectors. Man what a difference. Good Luck with the completion.
Ron
 
Mark,

That has come to mind. These lights are Amber facing forward and red facing back. I have them wired so they just come on with the lights. Really helps when you're cresting a ramp and the boat goes out of sight.

Yep...got the pics. So you just epoxied the threaded insert into the spring?
 
These lights are amber facing forward and red facing back.
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I have always in the past, been able to see the light reflection off the pavement to confirm that my trailer lights are working. LED tail lights, up on poles, will not do that for me.

As I think about these LED marker lights,,,,,,,,,,,,,,,,, I may wire them "in series" with the tail light on that side. If I wire in series, and the tail light goes out, the marker light will go out as well, alerting me to a malfunction. Normally wiring in series would reduce the light out put for an incadecant bulb, but I would think it would be negligible for LEDs. I'll have to do a bit of checking on that.
 
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