I have been so excited as I've come to the end of this project, but I didn't want to post until I was finished. Well I am now 98% done and can't wait any longer.
This started because a friend wanted me to CNC cut some parts for a half scale model for a teardrop camping trailer. At first I didn't care, but when I saw the parts I started thinking "this is the right size to make a motorcycle trailer".
So when he got the shell made he handed it over to me and I did the rest.
It weighs about 225 pounds. I've only pulled it a couple times (to the shop for paint and back) and I haven't really tested it yet for capability. I plan to do that in a parking lot before I carry it any distance. The hitch seems to allow plenty of lean angle, but I don't want to find out I'm wrong in a turn on a road.
So here goes:
It starts with some CAD work. This was all done in 2d
After cutting on the CNC router and some glue, screws, and staples, it's a skeleton.
A thin wood skin was installed on top with some relief cuts on the tightest curved areas.
Left and right sides are aluminum composite material. It's light and strong and was originally going to be my final finish.
A lot of money and parts went into this. I debated just buying a harbor freight trailer and robbing what I wanted from it, but settled instead on building from parts.
You can see here I have it clamped to the hitch tube (I'll call it). I was trying to determine the right length. I settled on very long. I read somewhere that the length from the center of the axle should be about 2-3 times the axle width. I don't know if that's right, but it works and is pretty balanced at this length also. The trailer is 30" wide x 4' long, and with the tongue, it's close to 8' long.
The boat window I found at Lanier Marine Liquidators. I figured this could keep water out as well as anything. This was a neat place, basically a boat junkyard. I found a few other possible windows, but this one slides open, has a screen and was the right size. It's from an Ebbtide boat. Once I got it home I realized it needed some work, so I refinished it.
After cutting the port hole for Maggie to have her head out of.
Lexan door, lot's of goof off and work to get this old paper removed.
CNC cut tail light housing with attachment tabs should match the shape fo the trailer. I formed this by hand basically. It's 0.03" aluminum, so I could tweak it until it fit right. I had predrilled holes to match the lights so that helped a bit. Drawing this took some time. None of this was modeled in 3d. So brute force was used to make this flat pattern.
Before bondo and painting you can see my tail light holders fit well, but not perfectly. Currently this is the one thing I'm not really thrilled about. The bondo job I did wasn't that great. You can't tell unless you look closely at the finished product, but it does bother me. Maybe eventually I'll refinish it.
Lexan port hole rain cover. Bending this in the oven was a pain and it still doesn't fit perfectly, but then it probably will never get used, so it's fine. I made a jig off MDF and 040 aluminum to the trailer shape. Baked the whole thing for a long time, slowly increasing the temp. At about 280 the lexan finally turned to a rubber like material.
I noticed Maggie kept hunting with her back leg for a step, so I thought this woudl do the trick. It's from a Honda Pacific Coast motorcycle. Good theory, but in practice she would just jump clear into the trailer with this in her way. I spent a lot of time chiseling into the 2x6 so this would be level and flush. All a wasted effort, but it was a good thought.
I installed rigid foam between the ribs before spraying on a liquid foam. This was mostly just to fill the voids so the spray foam would be more uniform. These are not attached in any way, just squeezed between the wooden ribs.
Freshly painted. Here is the only place you'll see the spray foam inside.
Rear bumper made of (you guessed it) aluminum composite material. Mirror finish. The plate should fit between the sloped lines. Attached with VHB Tape and silicone and will be screwed but I want to make sure the plate will hide the screws before I do it.
Finished lexan door and final step which is large enough for Maggie to use rather than jump over.
I printed a paper template that matched my original cnc cut files. I used it to mark my upholstry for rough fitting. Then I would put them inside the trailer and remark/trim.
I first installed carpet padding between the supports, then I installed a second layer over everything. Attached with spray adhesive.
Nearly finished interior. I used 2" foam and vinyl over 3/8" plywood to make these 3 cushions. They had to be small enough to fit through the door if I ever wanted to take them out to clean etc. I used automotive carpet on the walls.
Nearly finished interior. I just need some sort of head liner possibly.
This started because a friend wanted me to CNC cut some parts for a half scale model for a teardrop camping trailer. At first I didn't care, but when I saw the parts I started thinking "this is the right size to make a motorcycle trailer".
So when he got the shell made he handed it over to me and I did the rest.
It weighs about 225 pounds. I've only pulled it a couple times (to the shop for paint and back) and I haven't really tested it yet for capability. I plan to do that in a parking lot before I carry it any distance. The hitch seems to allow plenty of lean angle, but I don't want to find out I'm wrong in a turn on a road.
So here goes:
It starts with some CAD work. This was all done in 2d
After cutting on the CNC router and some glue, screws, and staples, it's a skeleton.
A thin wood skin was installed on top with some relief cuts on the tightest curved areas.
Left and right sides are aluminum composite material. It's light and strong and was originally going to be my final finish.
A lot of money and parts went into this. I debated just buying a harbor freight trailer and robbing what I wanted from it, but settled instead on building from parts.
You can see here I have it clamped to the hitch tube (I'll call it). I was trying to determine the right length. I settled on very long. I read somewhere that the length from the center of the axle should be about 2-3 times the axle width. I don't know if that's right, but it works and is pretty balanced at this length also. The trailer is 30" wide x 4' long, and with the tongue, it's close to 8' long.
The boat window I found at Lanier Marine Liquidators. I figured this could keep water out as well as anything. This was a neat place, basically a boat junkyard. I found a few other possible windows, but this one slides open, has a screen and was the right size. It's from an Ebbtide boat. Once I got it home I realized it needed some work, so I refinished it.
After cutting the port hole for Maggie to have her head out of.
Lexan door, lot's of goof off and work to get this old paper removed.
CNC cut tail light housing with attachment tabs should match the shape fo the trailer. I formed this by hand basically. It's 0.03" aluminum, so I could tweak it until it fit right. I had predrilled holes to match the lights so that helped a bit. Drawing this took some time. None of this was modeled in 3d. So brute force was used to make this flat pattern.
Before bondo and painting you can see my tail light holders fit well, but not perfectly. Currently this is the one thing I'm not really thrilled about. The bondo job I did wasn't that great. You can't tell unless you look closely at the finished product, but it does bother me. Maybe eventually I'll refinish it.
Lexan port hole rain cover. Bending this in the oven was a pain and it still doesn't fit perfectly, but then it probably will never get used, so it's fine. I made a jig off MDF and 040 aluminum to the trailer shape. Baked the whole thing for a long time, slowly increasing the temp. At about 280 the lexan finally turned to a rubber like material.
I noticed Maggie kept hunting with her back leg for a step, so I thought this woudl do the trick. It's from a Honda Pacific Coast motorcycle. Good theory, but in practice she would just jump clear into the trailer with this in her way. I spent a lot of time chiseling into the 2x6 so this would be level and flush. All a wasted effort, but it was a good thought.
I installed rigid foam between the ribs before spraying on a liquid foam. This was mostly just to fill the voids so the spray foam would be more uniform. These are not attached in any way, just squeezed between the wooden ribs.
Freshly painted. Here is the only place you'll see the spray foam inside.
Rear bumper made of (you guessed it) aluminum composite material. Mirror finish. The plate should fit between the sloped lines. Attached with VHB Tape and silicone and will be screwed but I want to make sure the plate will hide the screws before I do it.
Finished lexan door and final step which is large enough for Maggie to use rather than jump over.
I printed a paper template that matched my original cnc cut files. I used it to mark my upholstry for rough fitting. Then I would put them inside the trailer and remark/trim.
I first installed carpet padding between the supports, then I installed a second layer over everything. Attached with spray adhesive.
Nearly finished interior. I used 2" foam and vinyl over 3/8" plywood to make these 3 cushions. They had to be small enough to fit through the door if I ever wanted to take them out to clean etc. I used automotive carpet on the walls.
Nearly finished interior. I just need some sort of head liner possibly.
Last edited:
Nice job!
