
Converting a pop-up camper into a trailer is a great way to repurpose a ruined or unused camper. The process involves dismantling the camper down to its metal frame, deciding on the desired size of the trailer, and then building up from there. This may include modifying the frame, adding or removing parts, and deciding on the type of flooring and walls. The axle and braking system are important considerations, and one may choose to upgrade or keep the original parts. The final steps include painting the trailer and adding any desired features, such as a winch or special gates. With some creativity and engineering mind, one can successfully transform a pop-up camper into a functional trailer.
Characteristics | Values |
---|---|
Starting point | Pop-up camper with a ruined interior |
Frame | Metal, in good shape, sanded down and painted |
Size | 6x6, potentially extended to 6x8 |
Axle | 2000lb, possibly upgraded |
Flooring | Plywood or metal mesh |
Walls | Built from scratch |
Carrying capacity | 1,100 lb load capacity for a standard pop-up camper |
Materials | Aluminium, 1" x 2" rectangular tubing, 3/4" CDX plywood, 3/8" CDX plywood |
Features | Bi-fold tailgate, winch, storage compartment |
What You'll Learn
Dismantling the camper
The first step in converting a pop-up camper into a trailer is to dismantle the existing structure. This involves removing all the components that make up the camper, including the roof, walls, furniture, beds, appliances, and floor. It is important to be thorough in this process, stripping the camper down to its metal trailer frame. This provides a blank canvas to work from and ensures that the final trailer is as lightweight as possible.
When dismantling the camper, it is worth considering what parts can be recycled, reused, or salvaged. For example, the aluminium from the camper can be recycled, while items like the heater and sink can be reused or sold. This not only reduces waste but can also provide some financial benefit.
Once the camper has been stripped down, the next step is to decide on the size and dimensions of the new trailer. This includes determining the desired length, width, and height of the trailer bed, as well as the placement of the wheels and axle. It is important to consider the intended use of the trailer and what type of items will be transported to ensure the final product meets your specific needs.
In the case of the pop-up camper conversion, the original axle was kept, and the width of the trailer bed was narrowed to match the width of the axle. This involved cutting down the sides of the trailer frame, ensuring a neat and precise finish. The length of the trailer bed was also adjusted to match the length of a standard sheet of plywood, making it easier to create a new floor for the trailer.
The braking system was removed, and the parts were kept for potential future use. The winch, which was originally used to raise and lower the camper roof, was also removed, and the engineer considered how it could be reused in the new trailer design. This involved some creative thinking and problem-solving to incorporate it into the loading and unloading process for the trailer.
Overall, dismantling the camper is a crucial first step in the conversion process, providing a foundation to build upon and allowing for customisation to meet specific needs and requirements. It is a hands-on and detailed process that requires careful planning and execution to ensure a successful outcome.
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Choosing the right axle
Axle Load Capacity and Trailer Specifications:
Firstly, determine the maximum weight capacity required for your trailer. Consider the heaviest load you will be hauling, and choose an axle that can handle that weight. Calculate the Gross Vehicle Weight (GVW) and ensure the axles' capacity meets your needs. For example, if you require a 6,000-pound GVW with tandem axles, each axle must have a minimum capacity of 3,600 pounds. Check the VIN plate or label on the trailer to find the axle's weight limit.
Axle Type:
Different axle types have varying load capacities and designs. Assess the type of loads you will be transporting, as certain loads may require specific axle configurations or features. Consider the number of axles you need and select the appropriate type, such as torsion axles or leaf springs. For instance, Eye-Eye leaf springs are commonly used for lighter trailers, while slipper springs are more suitable for heavy-duty, multi-axle applications.
Axle Sizing and Load Ratings:
Understand axle load ratings to ensure safe weight distribution. Choose an axle with a load rating slightly higher than your immediate requirements to accommodate future changes or growth in your hauling needs. This provides a safety margin and ensures stability.
Trailer Dimensions and Weight Distribution:
Consider the trailer's dimensions and weight distribution to maintain stability and proper weight distribution. This includes assessing the length and width of the trailer, as well as the distribution of weight across the axles.
Suspension Systems and Terrain:
The suspension capabilities of the axle are essential, especially if you plan to operate the trailer on rough terrain or uneven surfaces. If you anticipate frequent or long-distance hauling, opt for a more robust and durable axle system.
Axle Distance (for Multiple Axles):
For trailers with multiple axles, consider the axle spacing, which is the distance between the centre lines of the axles. The axle spacing is primarily determined by the spring length. The standard heights for axle spacing are typically 33 or 35 inches.
Maintenance and Expert Consultation:
Regular maintenance is vital to ensure optimal performance and longevity. Conduct routine inspections, lubricate as recommended, and address any common axle issues promptly. If you have custom requirements or need further advice, consult trailer manufacturers or dealers who can provide valuable insights.
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Building the walls and floor
First, you will need to decide on the dimensions of your trailer. If you are starting with a pre-existing pop-up camper frame, you may want to match the width of your trailer to the width of the axle, as mentioned in one account. This involves narrowing the width of the trailer by a certain number of inches on each side. Alternatively, you can opt to keep the original width of the camper frame, especially if you intend to drive a tractor between the wheel wells.
Once you have determined the width, you can cut and shape the sides of your trailer. For the side frames, you can use rectangular tubing, such as 1" x 2" tubing. The height of the sides is up to your preference, but ensure it is sufficient for your intended use. For example, one person chose a height of 21" from the bed frame. If you desire more robust corners, you can use pressure-treated wood, such as 2" x 6" spruce, as this will help with longevity and reduce flex.
Now, it's time to choose your flooring material. Plywood is a popular option, and you can choose a thickness that suits your needs, such as 3/4" or 3/8" CDX plywood. If you prefer, you can treat the wood with a mixture of diesel fuel and used motor oil and then coat it with a sealant, such as Thompson's water seal. Another option for the floor is a metal mesh floor, which offers durability and breathability.
For the walls, you can use plywood, such as 1/2" pressure-treated plywood. Ensure the height of the walls matches the height of your chosen door. If you wish to add windows, now is the time to cut out the necessary holes. You can also add sheet aluminium to cover the walls, providing a sleek and durable finish.
Finally, consider adding some extra features to your trailer. For example, you can install car scissor jacks at the front and rear for added stability. Additionally, you may want to include a winch to help pull items into and out of the trailer. A bi-fold tailgate design can also be beneficial for loading and unloading.
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Electrical wiring
Step 1: Understanding Wiring Requirements
Before beginning any wiring work, it's important to understand the wiring requirements for your specific trailer. Consider the type and size of the trailer, as well as its electrical demands. Determine whether you need a 30-amp or 50-amp wiring setup and the corresponding wiring diagram.
Step 2: Gather Tools and Materials
Ensure you have all the necessary tools and materials, including wire cutters, crimping tools, heat shrink tubing, and the appropriate gauge wire. You will also need a trailer plug, such as a 5-pin or 7-pin trailer plug, depending on your trailer's requirements.
Step 3: Mounting the Connector
Identify the ideal location on your trailer for mounting the connector. This is typically near the rear of the trailer for easy access and connection to the tow vehicle.
Step 4: Preparing and Connecting Wires
Trim and strip the wire ends for clean connections. Use the correct wire colours based on standard coding: red for 12V power, green for right turn/brake, yellow for left turn/brake, white for ground, etc. Connect the stripped wires to their respective pins on the trailer plug, using crimp connectors for a secure and snug connection.
Step 5: Protecting Connections
Use heat shrink tubing or electrical tape to seal and protect the connections from moisture and corrosion. Ensure a watertight seal to keep the wiring safe from the elements.
Step 6: Securing the Wiring
Use zip ties or clamps to neatly secure the wiring along the trailer frame. This prevents loose wires that could potentially drag on the road or get damaged.
Step 7: Ground Wire Installation
Attach the ground wire (usually white) securely to the trailer frame. Ensure that the connection point is clean and rust-free for reliable electrical grounding.
Step 8: Testing and Finalising
Before finalising the wiring setup, test all connections to verify their functionality. Check that all lights, turn signals, brakes, and other electrical components work correctly. Once you've confirmed everything is in order, mount the connector securely in its designated location, protecting it from the elements and ensuring it won't disconnect during travel.
Additional Tips:
- Always disconnect power sources before starting any wiring work to eliminate the risk of electrical shock or short circuits.
- Wear appropriate personal protective equipment, such as safety goggles and insulated gloves, when working with electrical wiring.
- Work in a dry environment to avoid electrical hazards. If working in damp conditions, take extra precautions to keep connections dry and use waterproof sealants.
- Double-check your work for loose connections, exposed wires, or potential issues. It's better to identify and rectify any problems before hitting the road.
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Painting and finishing
Now that you've built your trailer, it's time to finish it to keep it looking good and protect it from rust. Here are the steps you can follow to paint and finish your pop-up camper trailer:
Prepare the Surface:
- Clean up the welds: Remove any weld splatter and grind down any uneven welds. Use a flat screwdriver, a flat-edged piece of steel, or a grinder to remove the "BBs" left by welding.
- Remove residue: Welding often leaves behind residue that can be removed with a wire brush.
- Remove oil and mill finish: New raw steel often has a rust inhibitor coating that needs to be wiped off with soap and water, along with any grease or oil.
- Remove rust: Use sandpaper, a wire brush, or sandblasting to get rid of any rust on the metal surface. Ensure that the rust is completely removed before painting.
- Surface preparation: For the best paint adhesion, it is recommended to sandblast the surface or use sandpaper to create a clean and slightly rough texture.
- Final preparation: Hang the frame or place it on a few points of contact for painting. Clean it thoroughly with soap and water, then let it dry completely.
Choose Your Painting Method:
- Painting: You can use spray paint or a paint sprayer to apply paint to your trailer. If using spray paint, look for enamel spray paint designed for metal surfaces. Apply one to two coats to achieve an even finish.
- Powder coating: Powder coating is a more durable option that involves electrostatically applying a plastic dust to the metal and then baking it in an oven. This method provides a robust and long-lasting finish but requires professional equipment and can be expensive.
- Epoxy primer: A two-part epoxy primer is a DIY-friendly option that offers excellent protection against rust. It consists of a base primer and an activator or hardener, which are mixed together before application. This method can be messy and requires a makeshift paint booth and small batches of paint due to the short cure time.
Paint the Trailer:
- Protect your surroundings: If painting in your driveway or garage, use plastic sheeting or a tarp to protect the area from overspray. Avoid painting on windy days to prevent paint from drifting onto unintended surfaces.
- Apply multiple coats: Depending on the paint you choose, you may need to apply two or more coats for complete coverage. Allow each coat to dry completely before applying the next.
- Paint the wheels: For a cohesive look, consider painting the white part of the wheels to match the rest of the trailer.
- Remove painter's tape: Once the paint is completely dry, carefully remove any painter's tape and paper used to mask off areas you didn't want to paint.
Finish and Maintain:
- Seal the wooden deck: If your trailer has a wooden deck, consider sealing it with a spar varnish to protect it from weathering.
- Maintain your trailer: Regularly clean and inspect your trailer to keep it in good condition. Touch up any scratches or chips in the paint to prevent rust from forming.
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Frequently asked questions
You can use a utility trailer frame as a base for your camper. You can either cut down the size of the trailer to match the width of the axle or modify the axle to fit the trailer. You should also consider the weight capacity of the axle and whether it needs to be upgraded.
You can use plywood, aluminium, and sheet metal to build the walls and floor of your pop-up camper trailer. For the floor, consider using either plywood or metal mesh. For the walls, you can use aluminium or plywood and cover it with sheet metal.
You can add features such as a winch, bi-fold tailgate, and car scissor jacks for stability. You should also consider the electrical wiring and lighting for your trailer.