Deckover dump trailer build

[f150skidoo]

Well I'm back to doing my somewhat annual trailer build thread, after taking 2019 off from building any trailers. What I'm building this time is a 5 ton tandem axle deck over dump trailer, The box will be 77" wide x 10.5' long. The trailer will have 20" tall fold down sides for a total of just over 4 yard capacity. What will make this trailer significantly different then any other trailer I have built is that it's going out to be hot dipped galvanized.

The first thing to make on the trailer was the rear hinges. The hinges are made from 3/8" plate that I cut and bent and use 2" DOM tube which rotates around a 1.25" pin. Next was to start building the tongue which consists of 5"x6.7 channel and 5"x3".188" rectangle tube for the cylinder to attach to. Next I cut and formed some 1/4" plate that goes under the front of the tool box. The purpose of that part is to distribute the force of the cylinder into the channel tongue. 3" square tube connects the formed 1/4" plate to the 5'x3" tube.

 

[f150skidoo]

Next was to cut the cylinder mounts from 1/2" plate then attach it to the 5"x3" tube. Since a deck over trailer sits higher off the ground compared to normal trailer I'm using a 5 position adjustable channel coupler to help give more adjustability options, and is mounted in a dropped position bias. I didn't have many options where I can mount the drop leg jack so the handle wouldn't hit the aluminum tool box. But I also don't like the looks when the jack isn't centered. So I ended up mounting the jack in a similar fashion to the traditional A frame couplers with the integrated jack, but the mounts i made are way stronger and is far enough back that the jack won't hit the tailgate if open

 

[nikerret]

Fantastic!

 

[Outlander]

Love these threads.....hats off for fab skills

 

[tarmy]

Beautiful fab work OP...

What tools are you using for bending plate?

 

[Dirt Rider]

Looks really nice, I'm looking forward to following along!

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[The Cobbler]

looking forward to this build, no doubt it will be awesome as usual

 

[bullnerd]

When I saw the title, I thought cool, This is what I want...then I saw the name! lol.

Did you have a plasma cutter for the last build?

 

[f150skidoo]

Beautiful fab work OP...

What tools are you using for bending plate?

I have a 50 ton shop press with a shop made brake, I have a assortment of press brake tooling in all different sizes of punches and dies. The max I can bend is 40" of 3/16" plate.

 

[f150skidoo]

When I saw the title, I thought cool, This is what I want...then I saw the name! lol.

Did you have a plasma cutter for the last build?

The past trailer builds I always had a Miller spectrum hand operated plasma, but this past year I upgraded to a Hypertherm 45xp and a 4'X4' Wright cnc plasma table.

 

[bullnerd]

The past trailer builds I always had a Miller spectrum hand operated plasma, but this past year I upgraded to a Hypertherm 45xp and a 4'X4' Wright cnc plasma table.

Awesome! You can see the difference in the design of the parts.

How to you like the Wright table? I've been following them for a while.

Their new tables look really well made and a great price.

Whats up with the Hobart 230? I thought you had a lincoln?

 

[mike93lx]

Definitely following along.

I'd love a custom trailer. I have found a pre-built that has most of what I want, but not everything.

 

[f150skidoo]

Awesome! You can see the difference in the design of the parts.

How to you like the Wright table? I've been following them for a while.

Their new tables look really well made and a great price.

I've had the tables since September and its been awesome. But if I new they were going to release their new design a couple months after I received my table I probably would've of waited for the new design. But now I couldn't imagine not having a CNC.

 

[f150skidoo]

The next step after building the tongue was to build the frame, I find it much easier and more accurate to weld the rear hinges to the channel when its flat on the welding table. I then squared up the frame, mounted the spring hangers , and attached the tongue. After fully welding the lower frame I flipped it upright and mounted the axles.

 

[The Cobbler]

looking good

 

[readhead]

Looking good as usual. The plasma table will really speed things up. What prompted this build? Did you have a specific need?

 

[f150skidoo]

Looking good as usual. The plasma table will really speed things up. What prompted this build? Did you have a specific need?

Last year my cousin bought a 10 ton Load Trail 8'x16' deck over dump trailer. Ever since then I thought it was a great trailer and I wanted one. But a 6x10 5ton deck over dump is difficult to find and is impossible to buy pre made with the features I want like galvanizing.

 

[theundermount]

looks great! I find it amazing how you guys can invision something and make it come to life. a true talent for sure

 

[bullnerd]

I think you missed my question about the welder.

What happened to the lincoln? I see a big Hobart in the pics. More power?

 

[f150skidoo]

I think you missed my question about the welder.

What happened to the lincoln? I see a big Hobart in the pics. More power?

I sold the Lincoln 210 mp last year because I wanted more power. I was going to buy a Lincoln 256, but a big box store up here stopped carrying Hobart’s large machines so they were clearing out their inventory.


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[bullnerd]

I sold the Lincoln 210 mp last year because I wanted more power. I was going to buy a Lincoln 256, but a big box store up here stopped carrying Hobart’s large machines so they were clearing out their inventory.


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Nice, that's what I figured.

 

[f150skidoo]

A little trailer update, I have the tires, tool box mounted for mock up of the dump box. Cylinders mounted and all the routing for the electrical and hydraulic lines are done so the lower frame is now complete. I also was able to pickup the 14 gauge sides and front bulkhead from a shop that I had bend them up for me.

 

[mike93lx]

What are you expecting finished weight to be?

On something this large, is the galvanizing still charged by the pound? Can they dip the whole thing or will you have to break it down?

 

[f150skidoo]

What are you expecting finished weight to be?

On something this large, is the galvanizing still charged by the pound? Can they dip the whole thing or will you have to break it down?

I have estimated the finished weight of the steel will be around 17-1800 lbs. After galvanizing and fully assembled I figure will be up to 24-2500 lbs. When i contacted the galvanizers I was told it would be by the pound. I'm going to deliver the trailer to them disassembled, lower frame, dump box, and the doors all seperated.

 

[The Cobbler]

do you use Cerka for suspension etc parts?

 

[f150skidoo]

do you use Cerka for suspension etc parts?

I get my axle and suspension from a guy in Brampton but everything else is from Cerka.


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[mike93lx]

I have estimated the finished weight of the steel will be around 17-1800 lbs. After galvanizing and fully assembled I figure will be up to 24-2500 lbs. When i contacted the galvanizers I was told it would be by the pound. I'm going to deliver the trailer to them disassembled, lower frame, dump box, and the doors all seperated.

Thanks

 

[f150skidoo]

A little update on the build. Since the trailer's deck height will be close to 3 feet tall if you need to get into the bed it would be a PITA to get in without a step. So I made a 2 foot wide step that is mounted into the rear bumper of the dump bed. The step is made from 11 ga. and has a bunch of dimple died holes. I cut large holes in the front and rear cross frames where other tubes will connect for free flow of the zinc in the galvanizing processes.

 

[mike93lx]

It would be awesome if you galvanizer would let you see the process and share some pics. I know it is just dunking it in chemical solutions, but I still think it would be interesting to see the end to end process

 

[Farmall450]

Hopefully the galvanizing holds up good. That is cool as hell and way better than powercoat.

 

[bullnerd]

I don't think that step is going to hold! lol!

I see you got a real milling machine also?

 

[f150skidoo]

I don't think that step is going to hold! lol!

I see you got a real milling machine also?

Ya I was getting tired of my mini mill always breaking on me. I really wanted a gear head drill press with a XY table but their hard to find and fairly expensive, so I opted for a old milling machine instead. But since I bought the mill I've upgraded to a new Hougen Mag drill and with the cnc plasma I almost never use the mill anymore.

 

[f150skidoo]

It would be awesome if you galvanizer would let you see the process and share some pics. I know it is just dunking it in chemical solutions, but I still think it would be interesting to see the end to end process

I was thinking the same thing, but with today health and safety protocols in large company's I'm doubtful they will let and visitors in the building. But it never hurts to ask either.

 

[bullnerd]

Ya I was getting tired of my mini mill always breaking on me. I really wanted a gear head drill press with a XY table but their hard to find and fairly expensive, so I opted for a old milling machine instead. But since I bought the mill I've upgraded to a new Hougen Mag drill and with the cnc plasma I almost never use the mill anymore.

Yeah, you've got a very capable shop going there, very nice.

 

[f150skidoo]

Yeah, you've got a very capable shop going there, very nice.

I'm pretty happy with the equipment that I have. But I would like to upgrade from my brake in my 50 ton press to a proper 50" 50 ton press brake, But I've never been able to find one used.

 

[f150skidoo]

Some more progress this weekend, First thing to do was build the perimeter frame. Next was add all the cross members and 2"x3" tube which will sit on the 5" channel on the lower frame. After I welded out the bottom side I flipped the bed up right and set it on the rolling lower frame.

 

[f150skidoo]

Once I had the bed sitting on the lower frame next was to get the rear hinges mounted to the dump bed, then I made the cylinders rod end mount. Before I get to ahead of myself I like to test lifting the bed to make sure theirs no interference with any parts. At the angle In the picture I measured the dump angle at 50 degrees and I still had a couple inches left in the stroke of the cylinder. Before I built the trailer I made sure that I sized the cylinder appropriately and placement in CAD and I figured out that the cylinder should dead lift 11,500 lbs. I removed the bed once again from the lower frame and started to build the front of the trailer, I bent up some 14 ga. sheet metal in a channel to stiffen up the front bulkhead.

 

[f150skidoo]

Next thing to build was the fold down side doors, I couldn't find a pre made hinge to work in my application so I made my own. I cut and bent up 1/4" plate to make the U brackets and the forged part is from a rear eye mount for a single axle leaf springs. I made a small mock up to test my hinges which was a good thing since I had to redesign the original brackets and then came to the current design which gives clearance for the weld beads. I then mounted the hinges to some 2x2 tubing which will be the lower door snifter so I can position and test the range of motion before assembling the door. Next I assembled and welded up the door and mounted the spring latches.

 

[f150skidoo]

After I finished building the two fold down side doors I started on the rear barn doors. I cut and bent 14ga. for the door skins then proceeded to build the door frame out of 2"x3" & 2"x2" tube. I was hoping to send the trailer out for galvanizing this week but I'm still waiting on the material for the floor which will be one single piece made from a 6'x12' sheet of 11ga steel

 

[nerraw117]

your dump trailer build looks amazing! If you ever want to sell some plans and some dxf files for me to cut out I would be your first customer!