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Comment: Here is the finished tear sitting proudly in the Sierra's on her maiden voyage. At 740lbs. it pulled so smooth and easy with no bounce that I had to keep checking the mirror to make sure it was still following and went straight arrow through heavy desert wind gusts. Keep clicking the center photo to watch it being built. ~~~ After 16 years nothing has changed except the roof vent cover has been replaced and the aluminum has a patina.
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September 23rd 2003 - This was where it starts. The axle and suspension finally arrived from R.W. Johnson.  It's a 4 drop with 1-1/2 springs on 39 centers. The hubs are 5 on 4-1/2 which is Ford's pattern.

September 30th 2003 - I chose channel over square tubing for several reasons. There is no place for moisture/water to settle and with tubing there is no way to seal the inside. Might be one of the reasons that almost all boat trailers are made from channel. In any event it's just a matter of preference and channel will be very strong in this application. Here the two inch channel is cut to length and is being clamped and squared up prior to welding. I clamped quarter inch steel plates at joints to line up rails prior to welding.

September 30th 2003 - A 25 degree notch was cut at the places on the outside rails where it will be bent to form the tongue.  A 50 degree coupling will then be welded on that will also accomodate the tongue jack.

October 2nd 2003 - After welding all but the front cross members the rails were bent to form a vee and then the front cross member was cut and welded in place.

October 2nd 2003 - The rails were welded together where the notches had been cut out for bending the tongue.  Also after squaring the frame a few gussets were installed to keep things from racking.

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Album last updated on Jul 28, 2008 - 12:43 PM
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