Pull behind trailer project

I'll be interested in how well you can get the carbon fibre & resin to adhere to the plastic, I always found it doesn't make a good bond to anything subject to vibration. You could always try drilling a series of holes so the resin effectively forms a rivet into the structure of the box.

These guys (the supplier I'll be using) advise to use this resin.

Is specially designed for flexible materials

https://www.ecfibreglasssupplies.co.uk/product/650-k-g-flex-epoxy-repair-kit

Forgot to mention, I'll be doing 2 layers of carbon. the G-Flex will be just on the first one and normal resin from there.

are you aware that one off trailers need an SVA test

are you aware that one off trailers need an SVA test

Yep

will need a O1 inspection for 150kg total.

I read about it on the trailer parts supplier and the gov.uk website, the nearest inspection station is either Aberdeen or Edinburgh

Making progress

Cover is all welded

Detail of welding process

Base is almost all done, will need to remove the temp frame to weld behind it

This is after sanding with new mini multi tool.

The entire surface will need sandig before the resin and carbon fibre is applied, so this finish is quite good

are you aware that one off trailers need an SVA test

By any chance you know how much it costs?

Slow but steady progress.

Cover is welded and sanded, ready for the carbon fibre layers.

The base is in progress. You will notice the top rim have been cut off (there is a bit of it showing on cover picture)) This is because I'm extending the base by 200mm to increase storage and to accommodate the wheel arches

I'm still considering if I'll be filling the grooves with some kind of lightweight foam because I'm not sure if the carbon fibre will be that flexible.

I'm designing the steel frame and the tow bar.

The frame will be built in 50mm square tube with normal steel to be painted while the tow bar is stainless steel.

Opted for a normal tow ball with traditional coupling and will be inserting a swivel so when the bike leans the coupling doesn't get stressed. This is still being designed because no way in hell I'm paying £200 for a swivel

This is likely to be 2 short 50mm square tube coupled with a M20 screw and Nyloc nut with washer. probably the screw will be welded on the trailer side and a ball bearing on the nut side.

But I'll update as I progress.

Looking really good [mention]husoi[/mention] I think you are right about filling those recesses with foam.

Cheers

Ian

Looking really good @husoi I think you are right about filling those recesses with foam.

Cheers

Ian

Thanks [mention]Ian Frog[/mention] I found out what they call "core material" these are sheets of very light material. around 35kg/m3, that will do the work

Latest acquisition.

Went on a site visit and found this beauty abandoned and sad

Ideal for my swivel

.

Axle bolt for the swivel

That looks substantial ideal for what you want.

Wouldn't want to drop that on your foot lol.

Cheers

Ian

That looks substantial ideal for what you want.

Wouldn't want to drop that on your foot lol.

Cheers

Ian

Definitely not

Now just need to get a ball bearing for the moving side.

That's me online placing the order for the steel for frame and towing bar

So today or tomorrow I'll have the steel delivered

Now that the tank cover is done it's time to keep going with this one

Placing the order for the carbon fibre, resin and all the bits for it.

I estimate the weight of the trailer to be around 60kg leaving 110kg for storage. I think it will be just enough for all the stuff the missus will want to carry

Photos of progress to follow

So today or tomorrow I'll have the steel delivered

Now that the tank cover is done it's time to keep going with this one

Placing the order for the carbon fibre, resin and all the bits for it.

I estimate the weight of the trailer to be around 60kg leaving 110kg for storage. I think it will be just enough for all the stuff the missus will want to carry

Photos of progress to follow

Er no you only have 90kgs storage as max 150kgs

As a thought have you weighed the kerbside Weight of your bike just in case it only allows a lower capacity than150kgs ie two thirds of bikes kerbweight ?

So today or tomorrow I'll have the steel delivered

Now that the tank cover is done it's time to keep going with this one

Placing the order for the carbon fibre, resin and all the bits for it.

I estimate the weight of the trailer to be around 60kg leaving 110kg for storage. I think it will be just enough for all the stuff the missus will want to carry

Photos of progress to follow

Er no you only have 90kgs storage as max 150kgs

As a thought have you weighed the kerbside Weight of your bike just in case it only allows a lower capacity than150kgs ie two thirds of bikes kerbweight ?

I stand corrected 90kg

The bike's curb weight is 312kg so the trailer can go to the max of 150kg

Nice job [mention]husoi[/mention] cant wait to see you both on your way and enjoying your holiday

So, get ready for several updates while I progres this one

so far work done is:

• 
  [list=]
• Welding box together

• 
  [list=]
• partial sanding of box base. The base will be partially sanded. According to www.ecfibreglasssupplies.co.uk expert I only need to sand the areas where the cloth is going to placed and the grooves I can just leave them empty instead of trying to force the carbon fibre around all the contours. This saves material and won't risk disturbing the weave of the cloth reducing it's mechanical strenght.

• 
  [list=]
• Order steel for both frame and towbar

• 
  [list=]
• Make list of necessary trailer parts. This is extensive and I won't be posting unless somebody will ask (politely )

The estimated total cost is sitting at £1,500 and is not expected to go over set limit of £1,800

£85 metal

£625 composites

£350 trailer parts

£70 IVA

£200 tools (partial value of all tools used as these are not exclusive to this project)

£20 ancillaries (likely to go up to max £100)

Interested in what trailer parts you used, and how your constructing frame...

I'll be posting pictures as I go along.

The frame will be rectangular with 2 bars converging to the hitch.

Decided for 10" wheel with suspension system.

Towingandtrailers.com have all inclusive kits that look very interesting and not too expensive.

As promised.

Template for towbar.

By making a template I avoid the risk of making the wrong part and have weld joints in the wrong place.

Used a Ø 21.5m plastic duct. cut to size and with simulation of weld locations.

Red tape indicates midpoint.

The only bit not done is the plate for the front bolt next to the pillion foot rest. This will be done directly with the SS plate. It's just a straight plate with a hole at the end and welded to the square tube.

This will be paused for now because I want to make sure the height from towbar to ground will match the trailer hitch so the trailer frame will be as horizontal as possible to minimise the pull effort.

This weekend update

Ordered the trailer parts and about to order a set of sock absorbers.

In conversation to a very helpful chap at Hafords and having my neighbour saying that his trailer was quite "jumpy" when not fully loaded I think it will be better to fit a pair of shock absorbers.

Incredible that how hard it is to find a pair without giving a car model End up finding these on Ebay.

https://www.ebay.co.uk/i/283903804820?chn=ps&norover=1&mkevt=1&mkrid=710-134428-41853-0&mkcid=2&itemid=283903804820&targetid=910259638509&device=c&mktype=pla&googleloc=9046883&poi=&campaignid=10195652606&mkgroupid=101938389037&rlsatarget=aud-629407027585:pla-910259638509&abcId=1145987&merchantid=115503351&gclid=Cj0KCQjw3Nv3BRC8ARIsAPh8hgJmg6oEdraDy6-YY4BUq2LsOqZhNtH6_W7gpsVHVEBa1oQr0v3rC6saAqZoEALw_wcB

Will just need to remove the springs and adapt them to the trailer.

For weeks I wasn't happy with the length of the box and what would be the end result of the trailer.

With a box 1.35m long the trailer would be just under the legal limit (2.50m from rear axle) I always thought that it would be a too long setting.

So...

Decided to chop 30cm off.

Started with the cover and next, after welding it together will do the same to the base so it will fit together.

https://www.ebay.co.uk/itm/293624532933

Just in case

Are you planing on turning the towing arm into a u ?

Are you planing on turning the towing arm into a u ?

Of course

It's symmetrical so I only need to do 1 side and the other (right side) is identical.

I'll be using the same principle for the diagonal from the front of trailer to the coupling.

While progressing the box and the frame, yesterday I made the swivel.

Very happy with the result even if took me ages to do it.

That happens when you have diy tools instead of professional ones.

I was considering having some kind of bearing to make the working smoother but the amount of movement won't be that big so the nut will be the moving part instead. The movement will vary the length of the frame by just a couple mm so I'm fine with it. This is similar to the ones I found on sale which rely on steel to steel movement.