Build your own - TalkTalkmyweb.tiscali.co.uk/threetenradio/BuildyourownTowingDollyttr.pdf · Build your own Towing Dolly Complete Step-by-Step Plans And Materials/Cutting List Gross

Build your own

Towing Dolly

Complete Step-by-Step Plans And

Materials/Cutting List

Gross Trailer Capacity: 3,500lbs Empty Trailer Weight: 1,050lbs

Empty Trailer Nose Weight: 90lbs

Copyright © 2005 Roseand

Materials List

¼” x 3” x 3” Sq Tubing 16 linear feet 3/16” x 2” x 2” Sq Tubing 11 linear feet ¼” x 3” x 3” Angle 6 linear feet ¼” x 2” x 2” Angle 25 linear feet ¼” Diamond Plate 8 square feet 1/8” Flat Plate 7 square feet 3/16” Flat Plate 10 square feet ¼” Flat Plate 25 square feet 3/8” Flat Plate 5 square feet 3” Channel (5lbs/ft grade) 17 linear feet 1 7/16” Round Bar (HRR) 1 linear foot ½” Round Bar (HRR) 3 linear feet 1 ¼” Schedule 40 Black Pipe 9 linear feet 1 ½” Double Heavy Wall Pipe 1 linear foot NOTE: The amounts shown above are for the EXACT needs for the plans detailed and do not include any natural wastage incurred during cutting. It is always wise to order slightly more materials at the outset rather than having to re-order small amounts later.

Other Items Required

SAE Grade 8 Bolts with Lock Washers, Flat Washers & Nuts 3/8” x 1” 4 3/8” x 1½” 8 ½” x 1” 4 ½” x 3½” 4 ½” x 4½” 7 ½” x 6” 2 ½” x 4 ½” high x 1 ½” wide U-Bolt w/washers & Nuts 2” Ball 7,000lb min Coupler Bolt-on Spindle 14” Rims & Tyres 9” x 19” x 32” Mudguards 3/8” x 150” Safety Chain with 2 Hooks Trailer Lighting Kit Spring Latches with ½” Shanks & Lock DISCLAIMER: As we have no control over the builders abilities or materials, we DO NOT WARRANT these plans for any type of suitability of use and offer them for experimental use only. IT IS HIGHLY SUGGESTED THAT THE FINISHED PROJECT IS CHECKED BY A PROFESSIONAL TRADESMAN BEFORE PUT TO USE.


STEP 1

SPINDLE SELECTION The picture below shows the kind of spindle that this design uses. These could be found by scouring the breakers yards and are commonly found on the rear of front-wheel-drive cars.

Many other types could be utilized and new items can be bought from trailer companies such as TrailerTek (www.trailertek.com). 13” or 14” rims should be used and matched to the hubs used.


STEP 2

SPINDLE MOUNTING COMPONENTS


STEP 3

AXLE & SPINDLE ASSEMBLY




STEP 4

TONGUE & COUPLER




STEP 5

TONGUE MOUNTING HARDWARE


STEP 6

RAMP POCKETS



STEP 7

RAMP POCKETS (cont.)



STEP 8

RAMPS


STEP 9

RAMP SPRING LATCH


STEP 10

MUDGUARDS, LIGHTS & NUMBER PLATE BRACKET


STEP 11

PAN PLATE


STEP 12

PAN FRAME






STEP 13

PIVOT ASSEMBLY


STEP 14

TONGUE, BRACES AND TYRES


STEP 15

CLEAN / PREP / PAINT Before painting, the entire trailer should be cleaned and free from rust and grease. To accomplish this, all surface areas should be wire brushed and/or sanded. If severe rust is present, sandblasting should be considered. The welded areas should be chipped of all slag or residue and wiped clean with paint solvent. One or two coats of primer paint should be applied, and one or two coats of top grade enamel as the final application. Paint according to the manufacturers recommendations and safety guidelines. Alternative finishes to consider are galvanizing and powder coating which will give the trailer a hard, durable finish.

STEP 16

WIRING Follow the wiring diagram provided or follow instructions that come with your lighting kit. The suggested routing of the wires is through the 3” square tubing where possible although external routing may be preferred. The routing of wires through or around the mudguards must be done in conduit to protect it from the tyres.

STEP 17

WEB RACHET SLIDE BRACKET


STEP 18

PAN INSTALLATION SUPPLY LIST (2) ½” X 3½” NC, SAE GRADE 8 BOLTS WITH WASHERS AND NUTS. GREASE All contact points where pan assembly wear bars meet the wear plates on the ramp pockets are to be cleaned and free of weld spatter etc. Apply grease liberally at all contact points. Clean and liberally grease the pivot pin assembly. Place the pan assembly in alignment with the pivot assembly, and carefully install the pin so that the bolt holes line up. Install the ½” x 3 ½” SAE Grade 8 bolts, washers and nuts to secure pan assembly. Torque bolts to approx. 80 ft/lbs and apply Loctite.


STEP 19

SAFETY CHAINS


STEP 20

ELECTRICAL WIRING The choice of Lamp Clusters is entirely up to you and what you feel looks right, but both Lamp Clusters should have Tail Light, Brake Light and Indicator. Below are some examples of suitable Lamp Clusters:

It should also be remembered that the right side light cluster also has to illuminate the number plate unless a separate lamp is used for that. For connecting the trailer electrics to the towing vehicle, a standard 12n trailer plug is used (shown here) and the following diagram MUST be adhered to.

12N Trailer Plug

PIN COLOUR FUNCTION 1 Yellow Left Indicator 2 Blue Fog Lamps (if fitted) 3 White Ground (chassis) 4 Green Right Indicator 5 Brown Right Side Tail Lamp 6 Red Brake Lamps

7 Black Left Side Tail Lamps

1

2

3

4

5

6

7

Female Male

Care must be taken when routing the wiring. It is suggested that wiring is taken through the frame of the trailer itself, (as shown earlier) and flexible conduit used where it is routed next to the wheels and tyres. If in any doubt, consult a qualified auto electrician and ensure everything works correctly before using on the public road.


Documents

Build your own - TalkTalkmyweb.tiscali.co.uk/threetenradio/BuildyourownTowingDollyttr.pdf · Build your own Towing Dolly Complete Step-by-Step Plans And Materials/Cutting List Gross