Cargo Trailer 5x8 Overland Conversion - Cherokee XJ Content

thatsagiven

Member
May 16th 2021 Update: Cargo trailer conversion is road ready. Here is a recent shot from our maiden voyage.

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I'm about two months into this already but picked up a 2004 5x8 Continental Cargo trailer. This is where I am aiming to post pictures of my progress for anyone who is interested to follow. I know there are lots of knowledgeable people on here and I could likely use some help.

Trailer is roughly 5 feet tall and has torsion axles. I got a pretty good deal on it but it is pretty rough around the edges. The goal is to have a basecamp we can setup for camping trips, a comfortable place to sleep, hang out in the rain. Full size queen (just about) and something the Cherokee can tow. It's roughly 800lbs empty and I am aiming to keep it under 2000lbs but we will see how it goes.

Ill try and get you all caught up, here is where we started:

Picked this up Jan 20th 2021


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Cleaned it up, not too bad.

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thatsagiven

Member
Started with the Cherokee Spare for some inspiration. Love that this is 5x4.5 bolt pattern.

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thatsagiven

Member
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Found a set of 3 Rubicon wheels for a good deal with decent tires. Bf Goodrich All Terrain KO2.

These are takeoffs from a JK originally so actually a 5x5 bolt pattern, but all three came with quality adaptors and they were off of a grand Cherokee.

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Test fit on the trailer, going to need a lift and rethink the fender placement. Drop hitch at least for towing.

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You dont really need fenders right? (I know I do :( )

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One more because I am stoked on this thing. I am going to need bigger tires for the Cherokee now.

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thatsagiven

Member
Insulation time. Started with this half inch Styrofoam Durofoam. Sealed both sides. a little annoying to cut and work with but has a vapor barrier already and a thermal barrier towards the aluminum siding. I did lots of reading on insulation and leaving an air gap between the siding and the insulation is supposed to make the biggest difference. I know the half inch stuff is not going to be the best isulation in the world but should be good for my climate.


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thatsagiven

Member
Got an RV door in really good shape, with frame and screen. Going to be replacing the window. I forgot to take a picture of it new (this is after cutting about 18 inches off). If I can find one Ill come back and post it.

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replaced the window with a black frame I got off fb marketplace.

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Shortened door. Measured once and cut twice on this one lol. I aimed to cut it down 18 inches to fit the side of the trailer, but miscalculated the floor vs siding. Oh well at least I could take more off. Chopped another 4 inches off at the end.

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thatsagiven

Member
Point of no return, did some cutting

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Still rocking the ol'PowerFist grinder with the guard on. Hasn't died yet. (Thanks Princess Auto)

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Can opener? Got some flooring as well.

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It fits!

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Ran out of daylight but got it all installed and sealed (silicone is a pain in the ass)

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Screen Door fitted, Turned out pretty good. Only nicked the screen material once with the grinder that I was using, Oh well that stuff is cheap and I am going to remake it with black screen door material.

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thatsagiven

Member
The framing is a little rough, I was trying to keep the ribs intact from the trailer wherever I can. We will see how that goes. I am really happy with how sturdy and how it came out.

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Now its starting to feel like a ghetto camper! haha. Done.

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At this point I sat back and admired my work. Beer Time! (there has been a few)

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thatsagiven

Member
Found some windows on craigslist. Did some tinting. (for my first attempt I am pretty happy with how one turned out.)

These are 23X 25 inches and non-opening. This means I will need to cut a rib to install them but nice.

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thatsagiven

Member
There was a roof leak when I got this, replaced the slats inside and now time to remove all the old lap sealant and do a cleaner more permanent job.

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Pain to get this all off but will be worth it!
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Pretty clean for the most part.

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The ends are the worse. Ill come back to these later lol, No more feeling in my finger tips.
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This stuff is great! Why did I get black... That doesn't match... yet.
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Need some warmer weather...
 
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thatsagiven

Member
Feb 6th

Insulation part 2, make a vapor barrier they said. I am reading that tuct tape is a Canadian thing, but I think I need a sponsorship.

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forgot to take more pictures here but got the cedar roof installed as well. At least a start. Looking less ghetto?

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At this point trying to decide if I insulate the floor as well. We will see..
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thatsagiven

Member
First Window installed, I should have taken more pictures of this but tuct tape, Butyl Tape and eternabond for the seam around the window and then lots of Silicone for sealant. I hate silicone..
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interior shot and installed some plywood for the walls.
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thatsagiven

Member
I feel like I should have stuck with one kind of Tuct tape lol, The red is cheaper and for interiors.. Also used some sprayfoam for all seams. Hard to see but this should should be pretty well sealed.

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thatsagiven

Member
Feb 12th 2021

Not pretty yet, but she is coming along. I am not 100% happy with the window install. Might take another stab at cleaning it up a little in the future.

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A little mockup with some diamond plate for the sides. Still haven't decided on a final color scheme. Have a few ideas but that vinyl door strip might have to go.

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Stretched the stock fenders about 3 inches and I think they will work out. I am debating spray bedlining them black when it gets a little warmer out.

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I think I am liking the look of this!
 
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