Well, I've been wanting an aluminum frame trailer for my jetboat for a while. A few months ago, I called Wesco Mfg in Columbia, SC for a price on an aluminum trailer to fit a 16 ft X 4 ft johnboat. Nearly 1700 dollars!! :shock: A little too high for me.
A friend of mine buys used trailers and re-works them, then sells them to make a little cash. Think of it as "trailer flipping" LOL He recently acquired 2 aluminum frame trailers, 1 was a single axle and the other was a dual axle, with V-bent crossmembers made of 1/4X3 aluminum sq tube. Well, since the bunk boards were U-bolted to the cross members and they were used in salt water, the electrolysis ate up the crossmembers to the point they were breaking. And instead of being bolted to the trailer, they were welded, which meant replacing them would require cutting out the old ones and welding in new ones.
So, he ordered the crossmembers, and when they came, they were not V-bent, but straight. And for 2 80 inch and 1 54 inch crossmember made of 1/4x 3 aluminum sq tube, he paid about 250 dollars (we figured it as a 12 dollars a foot, or, a dollar per INCH!! ) :shock: Ouch!
Between this and some other issues, he was frustrated with it, and said he was about ready to chop it up and take it to the scrapyard. I told him "don't do that, I'll buy it from you, I can modify it for my jetboat." He said he'd think about that.
So, the next day he called and asked if I was serious about buying the trailer, and I said I was, then asked what he wanted for it. He said 300 dollars, and I said "SOLD!" He said that also included 2 of the 4 brand new tires and rims. So, since he made me a deal like that, I decided to help him out and buy the crossmembers from him, as he wasn't able to use them and was about to eat 250 dollars.
So, right now, I've got 550 dollars in it, and have to spend just a little more for a new set of slider tracks and springs, new axle and new fenders, and it'll be done.
On to pictures.........
Here it is, as purchased. Take a good look, because it's about to undergo some major surgery.
Cross member, destroyed by electrolysis
Double axles. When completed, it will be a single axle, as my boat weighs about 1100 lbs, I don't need dual axles.
Here's my current trailer for the jetboat. Made from 2x3 rectangular galvanized tubing. Overall, it's in good shape. The last foot of the longitudinal members of the frame are heavily rusted, the bottom side is rusted out. Also, the rear crossmember is heavily rusted, not compromised yet, but I'm ready for an aluminum trailer and be done with all the unsightly rust.
Once I get the aluminum trailer built, I'll be donating this to my buddy that I bought the trailer from, to help him out, again, he gave me a good deal on the aluminum trailer.
OK, so right now, my existing trailer is 60 inches wide, by about 13 ft from the rear crossmember to the beginning of the tongue, where the 2 sides meet. The aluminum trailer is about 19 feet long, by 80 inches wide. So, it's gotta be cut down and made more narrow.
Here we go.....
CHOP, CHOP!
Old cross members and axles.
Removed the original tongue with brake system, the heavy winch post, and the 2 tires and rims that go back to my buddy.
And here's the tongue section I cut off, nearly 6 foot long (5 ft straight edge stood up in center, for reference
OK, as you saw in the photos, the front axle had a bend, and the rear one was straight. While the front was heavily rusted, the rear one was in good shape, so, my plan was to modify it. But you know how plans go.
Now, this REALLY p!sses me off....
I thought I was going to be able to clean up the surface rust, cut the axle shorter and use a sleeve, and be able to re-use it. Until I saw a hole drilled for the spring bolt....GRRRRRR :x :x :x When I saw that, I flung the axle across the driveway with a few expletives.
For the love of God, how hard is it to take a piece of 2" X 3/8" flat bar, punch a hole on center, and cut it 2 inches long, and weld the pad onto the axle? Using that method, the axle is strong. With a hole drilled....well, you might as well take a torch and cut a big notch somewhere in the tube. Because that hole lets water in, so then you have to contend with rust not only on the outside, but on the inside, too. Then, the hole itself acts like a stress riser, and once it starts rusting, guess where it breaks?
With all that said, I'm just going to bite the bullet and buy a factory axle with hubs for 125 dollars, as it's already hot dipped galvanized, something I'm not able to do when I build axles. Wasn't counting on that expense, but due to some $%^&# drilling holes in the axle, that's what I have to do.
OK, sorry for the rant....back to it
Need to draw it in, so the distance between the webs of the 2 beams is 3 inches, where the tongue will go.
Notch
.....and bend
There we go. Hated to have to cut it to make it bend, but that was the only way. I'll just V out and weld all the cut areas from both sides, then fish-plate with some 1/4" aluminum plate.
I figure on using a piece of the drop from the 80" cross member, to make a short cross member to tie the tongue into.
For all my cross members, I'm going to make end plates with pre-punched holes, so they can bolt to the flanges of the aluminum I-beam.
So, my next step is to make the end plates and weld to the cross members and bolt everything up. And to weld up the notched area on each beam and reinforce by fish-plating. Then attach the tongue, winch stand, etc. Then the slider tracks, axle, and running gear.
Will post more pics as it moves along.
