Sarge is always pushing me to go hunting, run trails, or camping. Well, as you can see, Sarge is not the most comfortable vehicle to sleep in. So about two years ago, I decide that I needed to get Sarge a "friend" that would make extended outdoor trips more comfortable. This started my search for an ORV trailer to pull behind Sarge.
I looked at all the usual suspects (Manley ORV, Rockbox, Turleback, etc.) but I just did not understand how they could cost $10k+ when they were all built on the old M-416 trailer design (the same trailer design that I use to pull behind my MUTT when I first got into the Army and has been around since the 1940s) and a couple hundred dollars of steel and labor. So I decided I would just build one myself!
This started my search and it took MONTHS to find a suitable candidate in my area that did not cost $1k+. I luckily found a guy less than 10 miles way that had one for sale for.... wait for it....
$250!!!
So of course, I immediately snatched it up! And thus started my ORV trailer build adventure. As you can guess, the trailer was not in the best shape but it wasn't unsalvageable either. I am going to try and document what I have (or had) done, as well as what I have purchased to put on it. I have a list of what I am still wanting to do or debating on doing as well. Finally, I have a section on what I would do differently (i.e., my regrets). I am doing this so that everyone else can do the same thing to their M-416s and save themselves several thousand dollars.
What Has Been Done
- In April of 2017, I purchased a used 1965 M-416 for $250. Bed had rust holes and end of frame was mush.
- Nabholz Industrial Services did the following work for me:
- Cleaned up surface rust.
- Welded in a second layer of steel in the bed and installed a stainless steel boat drain to resolve the issues with the holes and water retention.
- Removed lunette, built, and installed a 3-axis hitch (plans found here: https://tventuring.com/trailerforum/thread-65.html).
- Put a trailer receiver hitch on the rear for a bike rack.
- Replaced the rear frame section of the trailer with new steel.
- Created custom frame for my trailer lights (https://www.etrailer.com/Trailer_Lights/Optronics/STL35RB.html & https://www.etrailer.com/Accessories_and_Parts/Optronics/A33GB.html).
- Cut out the rear of the trailer and added a CJ tailgate to it for easier access to cargo.
- Installed BAL 23231, 31” C-Jacks under the rear of the trailer.
- Designed and installed a custom, vertically adjustable ladder rack and attached it to the trailer tub with Grade 8 carriage bolts and to the trailer frame with welding and Grade 8 carriage bolts from boltdepot.com.
- Installed a Raingler Nets universal net to secure cargo (https://raingler.com/collections/universal/products/2-inch-webbing-net-universal).
- Installed bolt plates from CustomTieDowns.com to attach the Raingler Net using Grade 8 carriage bolts from boltdepot.com.
- Installed 4 x 40 Lbs Bansbach Gas Springs, F3 M8 ball socket endfittings, and zinc plated brackets to help lift the rack system.
- Replaced all bolts with Grade 8, zinc plated bolts from boltdepot.com.
- Dexter 3500 Lbs axle with the following specs ordered (still to be installed):
- 3,500 Lbs straight axle
- 57" from hub face to hub face
- 39" from spring center to spring center
- Setup for spring-over
- Electronic brake w/parking feature
- 5 x 5 hubs
- EZ Lube
- 18" Jeep wheels powdercoated Prismatic Powder's Arney Green and fitted with used Cooper Discoverer ST MAXX LT295/70R18 tires from my Jeep that have plenty of life left for trailer use (I replaced the tires on the Jeep with Nitto Ridge Grapplers in LT285/75R18).
Here is what 'Corporal' looks like today:
As you can see, I still have some work to do. I will post more pictures as I continue building up Corporal.
Still To Do
- Purchase and install a rooftop tent and awning. I am pretty sure I am going to get one of the following:
- Cascadia Vehicle Tents (CVT) - $2,705.00
- Mount Rainier Extended Stargazer Pioneer (Earth Tone Green): $2,195.00
- Standard Pioneer Awning (79" Width in Earth Tone Green): $300.00
- Awning Mesh Room - Pioneer (79" Width): $170.00
- 72" Annex Channel: $40.00
- Smittybilt - $1,605.97
- Overlander XL (2883): $1,099.99
- Overlander XL Annex (2888): $299.99
- 6.5' Awning (2787): $205.99
- Tepui - $2,770.00
- Explorer Series Autana 4 (Tan): $2,300.00
- 6' Awning (olive green canvas/black car cover): $310.00
- 6' Mosquito Netting: $160.00
- 23Zero - $2,498.00
- BYRON: $2,199.00
- Glenrock 20 Awning: $299.00
- Have the tub bed-lined to color match my Jeep.
- Have the frame and rail system bed-lined black.
- Install wider fender flares (possibly built to match Sarge's) and have them bed-lined black.
Debating On What Else To Do
- Electrical & charging system? - have decided that I am definitely doing this. Here are the components I will use:
- Haul Master 2 1/3 cubic foot steel trailer tongue box
- Noco AC Port Plug with Extension Cord
- Noco Genius Gen2 2-bank 20 Amp On-Board Battery Charger
- Two (2) Optima D27F Yellowtop Batteries
- Blue Seas m-Series Mini Selector Battery Switch
- Blue Seas Blade Fuse Block - 6 Circuits with Cover
- OTRATTW Contura V, Single, Upper Dependent LED switches & custom rocker plates
- OTRATTW Six Position V-Series Switch Holder
- Propane tank mounted?
- C-Jacks for front?
What Would I Do Different
- I would have used telescoping, square tube to create the cross-members and collars on the ladder rack frame to allow for greater up and down movement and reduce some weight.
- Make sure the fab shop does not weld the cross-members to the rack uprights so that they can be adjusted in multiple ways.
- Make sure the fab shop does not accidentally weld the removable tub to the frame, thus making the tub un-removable!!!
Please feel free to ask me questions or leave comments on this.
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