The 4x4 Podcast Expedition Trailer Build Journal

jeepin_idaho

Adventurer
@Demo1986, thanks for the kind words! The podcast is really a great way for me to stay connected to the offroading and adventure community. I want the podcast to be something that entertains, educates, and inspired folks to get out an explore everywhere. How'd you find out about the show?
 

jeepin_idaho

Adventurer
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.

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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.

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Dan
http://the4x4podcast.com
 

jeepin_idaho

Adventurer
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.

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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. *
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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. **
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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. *
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Dan
http://the4x4podcast.com
 

jeepin_idaho

Adventurer
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.
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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.

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Dan
http://the4x4podcast.com
 
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jeepin_idaho

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

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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

Adventurer
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

Adventurer
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.
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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.

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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.
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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
 

jeepin_idaho

Adventurer
Thanks Mark! It tracked nicely on the trip down to see you but the true test will be soon. And the Jeep hasn't yet pulled the trailer a long distance yet. The expectation of adventure went up exponentially with the Jeep pulling thee trailer.

Sent from my SM-G900V using Tapatalk
 

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