Tag Archives: 4wd

Ultimate Off-Road Camper Trailer

G’day and welcome to another build.

It seems i cant keep still and since recently sold the slide on camper,  I have decided to turn the trailer into some sort of multi purpose off-road camper trailer. See that build here. 

Its going to have a small simplistic kitchen box on the passenger side and have my new James Baroud pop up tent mounted up top.. Its going to be open in the guts so I can roll on my ATV quad bike for weekends away, thinking a stainless keg welded to the draw bar for some sort of charcoal grill and maybe a box on the drawbar for my 12v fridge. Leaving the trailer empty somewhat, leaves it still a versatile trailer for all sorts.

Lets get cracking!

Starting off with my previously built trailer, and my new James Baroud pop-up bed. Its time to get the show on the road.

IMG_91492016-06-25 08.55.48_result2016-06-25 09.08.07_result


2016-07-09 13.16.22_resultAfter a bit of head scratching, a lot of thinking ahead and some precision welding, I have mounted my James Baroud camper up top. I have left 1350mm underneath for my ATV to roll straight on up.

2016-07-09 14.04.34_resultThere she is popped.  Haven’t even slept in it yet!. Comes free with a ladder and dish washer/bed maker! haha.,  and a pup chucked in for scale reference.

2016-07-17 09.00.56_resultA quick trip out to the farm to check the bike fits before I go any further and she’s in by a mickey whisker. Bit dodgy using planks. Better sort that out when i get back. It would also be a bit liable of tipping if not attached to the truck. Better make some corner stays too.

2016-07-18 16.17.24_resultI’m back at the shop, next was to make the tray accessible for the ATV. Using two fiberglass mesh grates I had lying around, (also used for my 4WD for bridging ladders or sand tracks)  I welded on some type of hooks and some removable chains and its done.

2016-07-18 16.17.43_resultCorner stays done.

2016-07-19 06.55.22_resultSimple, and easy to make.

2016-07-21 09.55.52_resultNow before I get carried away with the kitchen, above that I saw an opportunity to maximize the space up top and extend the platform to accommodate my OZtent / 30 second tent.  The end plan is, is to have an awning stretch out over the kitchen then my Oztent attach to that for a sort of room to use for either somewhere to hang out of the sun or rain, or a second bedroom for kids or guests.  More on that later. So I thought i better make provisions for the Oztent now.

2016-07-20 15.34.28_resultBeing a metal fabricator, what better way to keep your tent clean dry and out of the elements than in a custom made alloy waterproof box!

2016-07-20 15.35.18_resultFits in like a cock in a sock. Even room for fishing rods, tent poles, snowboards/skis, extra awning crap etc.

2016-07-21 11.06.32_resultOztent box installed, new side awning installed. You beauty! Time to start the kitchen!!

2016-08-17 14.39.43_resultSo the kitchen box somewhat resembles a toolbox. Made from 2mm aluminium and made to fix specifically to fit in that area on the side of the trailer.

2016-08-17 17.11.05_resultNow the hard part. The layout.  This thing is a lot bigger than i imagined…

2016-08-17 17.53.01_resultI have decided to put in a divider at the last minute.  I think having a kitchen on one side and storage on the other would be a more practical use of space.

2016-08-17 17.23.56_resultGetting the divider in seemed somewhat impossible, as its bigger than the opening and should of been inserted before the box went together. Lucky for the SKYHOOK 2000! (see the build here). !

2016-08-17 18.18.40_resultNow a nice cover trim to finish off. Also completing the door jambs.

2016-08-26 13.25.16_resultDoors made, decided on a bi-fold design so the bottom half will be a bench top and the top half will have an LED strip light attached. Using packers here to get the gaps all even and parallel before installing the hinges.

2016-08-26 16.59.36_resultDoors on, weather/dust seal on, Starting to take shape.

2016-08-27 09.05.25_resultSlowly everything is finding a home. Trying to make it as practical as possible with everything within an arms reach. With a weekend booked away camping i better get a wriggle on.

2016-09-11-09-59-31_resultWith the drop down door fitted, here you can see i have made some custom internal ribs. This will give the door support and also fill in the inside as soon it will be laminated with a sheet of stainless.

2016-09-11-10-03-28_resultUsing a tube of expanding foam to fill in the gaps, itll be solid and insulated.

2016-09-12-09-22-18_resultAll sanded and ready to glue on a sheet of stainless steel.

2016-09-13-18-47-43_resultBench and LED strip light finished. Note the stainless bench still has the white plastic protective film on it.

2017-02-23 15.52.03_resultFinished the other doors, thus completing the kitchen and storage box. The front compartment i’m just going to leave empty for now until i decide what to put in it.

2017-02-23 13.50.17_resultRamps work a treat.

2017-02-23 13.49.59_resultOutriggers are great for when the trailers not attached to the ute.

2017-02-24 07.10.58_result

2017-02-24 07.15.40_resultAs you can see, the quad is a tight fit. No ropes are really needed to hold it in.

To be continued…..









DIY 4WD Box Trailer


After building my slide on camper,  (seen here) Slide on camper I have decided to build tough little box trailer to complement it.

This way I have the option to either put the camper on my ute as previously or tow it behind on the new trailer. It will also enable people to use the camper if they don’t own a utility or a potential buyer who wants the whole package!

The reason to build a trailer over buying one are a plenty, this way I get exactly what I want and save a few dollars in the process. Also my dad has been wanting a new trailer for decades and thought it would be nice if I built one we could both use. And to no cost to him.

Its going to be quite small, have heavy duty 1600kg 4WD suspension, 33″ 4WD tyres (Cooper ST MAX’s), made from galvanized steel, have an internal box storage size to perfectly fit 4 x 900 x 500 x 400 Pelican space cases, and the top made to the same size as the camper so when its paired it will work and look awesome.

This is my story,

IMG_8611Like all ideas of mine, they begin their fruition on a piece of paper. Starting with rough sketches of what comes pouring out of my mind the design slowly takes shape.

IMG_8613Putting dimensions on sketches gives me parameters to work with, like a limit to what I can do within the space and also the goal or reason for build.  In this case, the tray top needs to match the camper so 2050 x 1850  is the ideal size.

IMG_8612I would like the inner box compartment to fit my pelican space cases which measure 900 x 550 x 400 each so an internal size under the camper of 1800L x 1100W x 400H min.

IMG_8641Next is to get a bit more serious. Without going into too much detail using Autocad and drafting up proper drawings, this one has all i need to do the job. From this drawing i have also worked out the wheelbase and most importantly the axle length which i can now order to get made to size.

IMG_8642Here we have the side elevation above and below an isometric view of the parts for the frame/chassis with part numbers. From this drawing I can start cutting the lengths of tube up.

IMG_8603Next step was to get cracking! Here we have the box section chassis made from 40 x 40 x 2.5 Duragal SHS tacked together. All cut from that crappy drawing above. No CAD necessary.

IMG_8807There’s the frame fully welded and the tailgate made and installed. Its upside down by the way,

IMG_8808My Christmas has come early!  Got a delivery today. The hardware!

IMG_8810Basically everything i need to make a trailer. Minus the wiring , lights wheels etc.

IMG_8812A few late hours later I have welded the hangers and installed the shackles, fitted the springs and are now fitting the custom made axle.

IMG_8813Axle on, electric brake hub on.

IMG_8814Getting excited!  (i am only dry fitting the bearings tonight as I need to borrow a bearing grease packer off a friend tomorrow

IMG_8834Prepared earlier, was a new set of Cooper ST-Maxx.’s 33″ on 17″ steel rims.

IMG_8819Wheel on, mudguard just sitting in there at this stage. Its looking pretty good, so far the dimensions are matching the sketch. Almost ready to make the draw bar and flip it over.

IMG_8829Draw bar on. Making it quite long as its easier to reverse, able to jack-knife for turning around on tight 4WD tracks and also my to point under my ute is a fair way under the tray.

IMG_8835On its wheels. Tail gate done!.

IMG_8837There it is, the rolling chassis.

IMG_8836Looking at how the height came together i think its a bit high, from here I will take the axle out again and put it on top of the leaf springs which will lower it about 130mm.

IMG_8955There thats better. see how the wheel is more inside the mudguard now. Also checking to make sure the pelican cases fit.

IMG_9137Mudguards painted, now to fit the gal sheet metal.

IMG_9138Im going to use a 2mm gal sheet for the bottom and 1.5mm for the sides to reduce the weight a bit.

IMG_9149Sheet metal done.  It has been stitch welded on so there is no rivets or screws then every seam and join i have used a flexible sickaflex 11FC to keep the edges from collecting dirt and water and rusting out. Its will be painted over later on.


So,  I have missed taking a few photos of wiring the lights and finishing painting etc but she’s finished now.

As you can see in the pics below, its great all rounder, versatile solid trailer great for any purpose. Unbreakable and rustproof. With electric brakes and heavy duty 4wd suspension its a pleasure to tow and forget its even there sometimes.



Next up is to mount the slide on camper on top and see how she goes.

Here’s a few photos of my slide on camper mounted on the trailer. These two pair up perfectly and giving me ultimate versatility to either tow it and leave the ute tray empty, put the camper on my ute for a bit more remote travelling or just using the box trailer as a good all-rounder and leave the camper on its legs.

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2015-10-10 12.52.26_result

2015-09-30 07.32.57_result

2015-11-08 13.22.03_result

2015-10-07 12.14.25_result

2015-11-08 13.36.03_result


Thanks for reading and stay tuned for more interesting projects to come!.

Next up:  Turning that trailer into the ultimate off road camper!!

If you want to see the slide on camper build.  See it here!

Camper Trailer

From the passion of camping and being outdoors it was time i built myself a camper trailer. The concept was to basically have a 4wd style trailer, big wheels, lots of clearance and have everything on it imaginable. The thought of just being able to hitch it on and know straight up you’ve packed everything. No need to fumble around packing this and that, just get it and go. And when you have arrived at your camping spot, everything is accessible easily and quick- beds already made, kitchen already set up. no unpacking or setting up tents etc.  Here is my story.

I hope you enjoy the read and don’t forget to subscribe by pressing the follow button at the bottom right of this page!

Canopy FrameWhat originally  was the canopy and tray off my 4wd ute, I was contemplating building a longer tray so thought about making this tray into a trailer..



IMG_0968And like that, the tray was off.  Now for the fun part…

IMG_1096 IMG_1101First the chassis was built, all suspension and wheels fitted.  After these shots, i decided to change the hubs to electric drums.

IMG_1115 IMG_1114Completed chassis with draw bar done, so are the tray mounts.

IMG_1174A few coats of paint and the tray is fitted.

IMG_1241All new Alco 4wd hitch, heavy duty jockey wheel, handbrake set up and the wiring loom.

IMG_1250IMG_1251Next to build was the two stainless steel tanks. One a 160 liter water tank and a 180L diesel tank. All made from 316 stainless fully TIG welded. I make these sort of things at work all the time so no guess work here.

P1040153The finished tanks.  Ready for install.

IMG_1289The tanks fitted. Note the rear tank is angled for a good exit angle when 4wding. After this shot the rubber strips were inserted between the stainless steel hangers.

IMG_1553 Here we have the aluminium removable false floor, It was made to store 6 of these huge storage containers and still be able to sleep up top.

IMG_1618 IMG_1434Next was the custom box made with duel fridge slides. One side was for a food fridge, the other beer. The top box was a toolbox i had lying around. It worked well as the shape would be good for the wind deflection and this was now going to be the home for the duel batteries.

IMG_2580The duel 12v 75AH sealed gel batteries & switch panel. This is wired to the plug at the hitch. My battery management in my 4wd will register when i plug in the trailer and charge these when we are on the road. I was going to add solar to this project but never got around to it.

IMG_2481Next was the kitchen. I knew what i wanted before i started so this one went pretty smooth. We make boxes and all sorts at work so basically like a toolbox with fold down front. All made from 3mm alloy tread plate with weather & dust seals.

IMG_2581The kitchen finished and installed onto the draw bar.  The taps there are hot (from the gas hot water heater) cold in the middle and the third is to fill the water tank.

IMG_2591The draw finished in the kitchen. There is enough plates bowls pots pans etc for 2 people comfortably.

IMG_2582Next is the gas hot water heater. Running off a 9kg bbq gas bottle this pumps out piping hot water on demand. The stone guard also serves purpose to hold the shower hose and give a little privacy/wind protection.

IMG_2583The water heater cover/stone guard closed.

P1040337The water pump and filter hidden away safely with good access if needed.  All plumbing is done using BSP pipe threaded fittings and Auspex pipe. No hose clamps here!

P1040338Here is the diesel high-flow transfer pump and bowser. works a treat.

P1040342The switch panel which hides and protects the two batteries.

P1040341My dog Jake sitting on the false floor.

P1040310The trundle tray which holds all tent poles, ropes, pegs, awning canvas, hammock and the like..

Now the finished photos!P1040333 P1040327 P1040325 P1040320 P1040318 P1040314 P1040309 P1040299

After this project was finished we drove from Sydney to Byron Bay via Coonabarrabran/Narrabri , mostly dirt roads for our end of year holiday. The trailer didn’t miss a beat and did everything and much more. Oh, besides a flat tyre. Ill add a few pics of our trip below.

P1040221 P1040219 P1040231 IMG_2619 IMG_2614 IMG_2634 IMG_2639 IMG_2652 IMG_2658

I hope you enjoyed the read. If you have any questions feel free to leave a comment below and ill try and reply asap. Cheers.


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