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Thread: Personalizing a new, inexpensive bumper pull car hauler trailer

  1. #1
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    Default Personalizing a new, inexpensive bumper pull car hauler trailer



    We recently were asked to make some modifications to a clients brand new trailer. The trailer in question is a basic, inexpensive, 7000 pound capacity, bumper pull car hauler. Shown here:







    The desired modifications include adding a little structure in order to make it a tad more sturdy, a standard 2" receiver hitch, good amount of lockable storage, and a receiver mounted winch with both wired and wireless controls. These modifications along with the client's drop in anchor points and Mac brand straps, should make for a decent towing platform for years to come.

    To start, we will need to add a little structure to the tongue of the trailer. Here is what we started with:



    Cut a piece of angle iron to serve as a lower cross member to tie the frame sides together while tying into the deck structure as well. It is notched to fit inside of the frame rails and to allow the wiring to still pass along the driver side frame rail.





    And tack welded it into position:






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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    The front top rail was then cut to accept a standard 2" receiver hitch:





    And a piece of tubing was cut to fit between the new cross member and the bottom of the hitch. A 1/4" plate was welded inside of the tubing, along the top and bottom as well as plug welded in a few spots, to provide some extra support as well as so it could be drilled and tapped at a later time for the future storage box mounting.





    Then welded the pieces into position:










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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    Next up is adding some gussets to the sides of the top rail, as well as welding out the tops of the angle iron that attaches to the top rail. This wasn't done from the factory.

    Gussets:



    Sides of the top rail prepped:







    Welding gussets into place:







    Welded the tops of the angle to the top rail:





    Completed gusseted and welded top rail:






  4. #4
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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    Mounting for the aluminum lockable storage box welded into position and drilled and tapped:







    Mounted the aluminum box to the front of the trailer using some mounting plates and bolting it to the trailer:












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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    Our client want to be able to store the multi-mount winch within the lockable box. It will easily fit, but could slide around within the box. That much weight constantly shifting, and banging into the thinner aluminum walls, will eventually damage the box without reinforcement. So it will get some to the lower 1/3 of the box.

    We start by cutting some small c channel and using our custom shop built punch press to put some speed holes through it.



    And started assembling the pieces together by welding:













    And installed the assembly onto the trailer:








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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail









    Painted:









    Painted with box installed:










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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    With the structural work completed, we start on the multi-mount winch setup. The client opted for a NOS Smittybilt XRC8 winch after seeing our setup that has been abused for the past 7 years and yet id working well still. They also opted for an off the shelf multi-mount. And an inexpensive wireless remote setup for it as well. and a nice wiring quick connect setup for the truck.

    The NOS winch:







    Wiring:



    Multi-mount:


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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    Assembling:















    New setup verses our 7 year old setup:


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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    Mounted to the trailer:









    Stored away in the lockable aluminum box:



    Finished product:






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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    And I am just trying to figure out how to fabricate a hi-lift mount for my rear bumper....looks nice....is there anything in the box to keep the winch from sliding around....I know you reinforced the box, but still, I don't think I'd want that thing sliding and banging and bouncing around.
    ___________
    James Orofino
    1970 CJ5
    1958 Willys Wagon
    2010 Tacoma TRD

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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    FINOCJ previously posted:
    "looks nice....is there anything in the box to keep the winch from sliding around?"

    Thank you for the kind words.

    No, there is nothing other than the exterior reinforcement. The client did not want anything else. Honestly I had to "talk" him into any reinforcement. As he put it, the box is for holding straps, tie down anchors, and spares. The winch will ride in the hitch, and only be stored in the box.

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    Default Re: Personalizing a new, inexpensive bumper pull car hauler trail



    I like the gussets on the rail, my trailer could benefit from that.

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