Auburn
Well-known member
For several months now I have been considering building my own trailer. I have a 1992 bushtec which is very good, but it has some short comings for how I use my trailer. I was inspired by some of the ideas that Northwoods Snowman used in this thread. Specifically, the trailing arm system and shock mounting. The current bushtec is 38' wide x 69" (front of cooler to back of trailer) and over all length of 84"
The bushtec places an ice chest on the tongue and with the wheels located 70% of the trailer length, it puts a lot of weight on the tongue that needs to be balanced somehow or you have a tremendous tongue weight on the bike. Also my trailer is shorter than newer models, which contributes to the stability of the trailer.
With that in mind here are the goals for the build:
better weight distribution
keep air shock system
improve suspension
enclose the ice chest inside the trailer over the axle area
carry a mounted spare trailer tire
carry spare FJR tires F&R (on longer trips to remote areas) inside the trailer
maintain similar size of trailer, lengthen tongue, and keep same width.
source parts that are off the shelf and common to get.
The new trailer has the following dimension:
overall length 100", with an enclosed are of 38" x 75" inches (tongue grew 10" and the body grew 6")
bottom of trailer is welded up using 1/2" x 1" .063 wall tubing for the perimeter and cross members except the one used to attach the trailing arms which is 1" square .063 tubing.
here is a mock up (the 1.5" rails are just supports to put up on the saw horses to make easier to work on) trailing arms set at about ride height w/ 4" of travel typical, could be more with more air in the shocks
Shocks attached to the trailing arms to check clearance to inside of trailer and wheel travel, alignment, etc... set at 4" of travel between top of trailing arm and bottom of frame. Bushings should be here later this week for the trailing arms. that will tighten up side to side travel
Axles in place, upper supports cross members in place, longitudinal supports mocked up and one wheel in place to check travel, alignment, clearances
More to come as I progress. Haven't decided on what the panel will be, probably diamond plate ALU, but might use sheet metal in the 22 gage range. The floor will be 1/2" marine grade plywood. A little bit of weld cleanup to do...
The bushtec places an ice chest on the tongue and with the wheels located 70% of the trailer length, it puts a lot of weight on the tongue that needs to be balanced somehow or you have a tremendous tongue weight on the bike. Also my trailer is shorter than newer models, which contributes to the stability of the trailer.
With that in mind here are the goals for the build:
better weight distribution
keep air shock system
improve suspension
enclose the ice chest inside the trailer over the axle area
carry a mounted spare trailer tire
carry spare FJR tires F&R (on longer trips to remote areas) inside the trailer
maintain similar size of trailer, lengthen tongue, and keep same width.
source parts that are off the shelf and common to get.
The new trailer has the following dimension:
overall length 100", with an enclosed are of 38" x 75" inches (tongue grew 10" and the body grew 6")
bottom of trailer is welded up using 1/2" x 1" .063 wall tubing for the perimeter and cross members except the one used to attach the trailing arms which is 1" square .063 tubing.
here is a mock up (the 1.5" rails are just supports to put up on the saw horses to make easier to work on) trailing arms set at about ride height w/ 4" of travel typical, could be more with more air in the shocks
Shocks attached to the trailing arms to check clearance to inside of trailer and wheel travel, alignment, etc... set at 4" of travel between top of trailing arm and bottom of frame. Bushings should be here later this week for the trailing arms. that will tighten up side to side travel
Axles in place, upper supports cross members in place, longitudinal supports mocked up and one wheel in place to check travel, alignment, clearances
More to come as I progress. Haven't decided on what the panel will be, probably diamond plate ALU, but might use sheet metal in the 22 gage range. The floor will be 1/2" marine grade plywood. A little bit of weld cleanup to do...
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