Member Since: 26 Oct 2012
Location: Bristol
Posts: 2021
O ummm august which year??? 07 Java Black TD V6 D3, EGRs Blanked, Tow bar, Full dog guard & divider, LED Spots , DRLs, GG ATs, RLD Sump guard, RLD Spare Wheel Protector, D4 LED Rear Lights, Limo tints on boot and Midnight tint on rear windows, Kenwood screen with Garmin nav, Rear cameras, D4 Steering wheel with flappy paddles, T-max split charge system, Tree sliders, Prospeed roof rack & Ladder, Alisport fast road inter cooler,
Massey Ferguson 35x
Sankey Narrow Track Camping Trailer (Gone but to a great home)
Mine has to be done for Billing at the end of July, so I had a little time on it today
First up I added the diagonal braces I wanted for roof support.
Better pic of the other side later on
I'd messed about last night with the tent, and now having the awning too decided to move the RT to one side, so I've had to add to the roof frame to be able to mount it
Then it was grind the welds flat, and Aluminium sheet time
Started with the roof, I removed the frame and worked on it on the floor under the carport out of he sun I had to do it in 2 pieces due to width so made sure there was a good overlap.
All the panels are been fitted using Tiger Seal to bond and seal them to the steel frame, then mechanical fixings of 4.8 mm sealed end Aluminium rivets
Refitted the frame having added a neoprene foam seal between trailer body and frame
Next came the front, this is angled, I was going to fit the sheets in sections, but decided I'd have a go at bending the Aluminium sheet, so noted the angle using a bevel gauge
Then using some lengths of firewood timer I made a bender , I have a fairly hefty bending press, but the sheets too wide at 1.6m
Then with some brute force, I bent the sheet to the right angle
Then fitted it
Next came the sides
So that leaves the rear and upper tailgate to sort, won't get a lot of time tomorrow, but we'll see
Inside shot
It's no RLD pod or Wiggs EXPO trailer, more function over form, as I want to be able to still use the trailer as, well a trailer, once the edges / sealant are cleaned up and it's all painted, I think it'll look ok and function fine Altox GSM FBH controller thread
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Owner of the original "Beanie" grille
D4 & RRS style D3 grilles made to order
14th Jun 2014 7:04 pm
Iguana
Member Since: 14 Oct 2013
Location: 'Sunny' Zomerset
Posts: 9424
Aug 2018 I mean
Beanie, great progress, love the look and thanks for the pics of the braces - will help me indeed
Where did you get the foam seal from, how is it attached? I'm guessing to the bottom of the frame so lifts off when you need to use it as a normal trailer Iggy/Ieuan
Current LR =
2015 RR Sport Autobiography
&
1992 Land Rover Defender Camper
- Gone but not forgotten:
MY10 D4 GS
MY05 Disco 3 'S'
MY14 FL2 HSE manual in Blue
MY15 Disco 4 HSE Lux in Santorini Black
MY08 Disco 3 SE manual in Buck Blue
1960 Series 2 88" (No idea why I sold it!)
good work could not do that with mine 5mm wont bend like that Home of RLD Hidden winch mounts Spare wheel Locks Trailer Body Fabrication ray@rld-tech.co.uk D3/4 sump plates MY 14 sump plates and the Discovery Sport wheel protectors Discovery 5 wheel locks
more Helsport tents and other things for camping Law of Mechanical Repair:
"After your hands are coated with grease, your nose will begin to itch and you'll have to pee!"
IID Pro MV License - D3, D4 & RRS - Enabling, Updates, D4 & RRS Timed / Remote Climate, D4 Bluetooth fitting
PM me for details
Owner of the original "Beanie" grille
D4 & RRS style D3 grilles made to order
14th Jun 2014 7:44 pm
Iguana
Member Since: 14 Oct 2013
Location: 'Sunny' Zomerset
Posts: 9424
Top man Iggy/Ieuan
Current LR =
2015 RR Sport Autobiography
&
1992 Land Rover Defender Camper
- Gone but not forgotten:
MY10 D4 GS
MY05 Disco 3 'S'
MY14 FL2 HSE manual in Blue
MY15 Disco 4 HSE Lux in Santorini Black
MY08 Disco 3 SE manual in Buck Blue
1960 Series 2 88" (No idea why I sold it!)
14th Jun 2014 7:58 pm
sailorboi
Member Since: 26 Oct 2012
Location: Bristol
Posts: 2021
Greg top job there
Has given me some new ideas for mine when I get the frame going I am so so itching to get back home now and start welding some box section together..... hurry up July 18th ish
Going to put my order in too for some sheet but sadly will have to collect it as they won't deliver the amount I think I might need
Also where did you get the rivets from? I am struggling to find all Aluminum sealed ones. That foam stuff is good I have got a roll ready to go
Iggy you are on 2018 it is Ok now realistically I hope to have a water tight body before I go back to work mid September, so about a month and a half once I get home. Fingers crossed no delays
Also what did you use to extend the brake rod just some normal rod? Then thread the ends?07 Java Black TD V6 D3, EGRs Blanked, Tow bar, Full dog guard & divider, LED Spots , DRLs, GG ATs, RLD Sump guard, RLD Spare Wheel Protector, D4 LED Rear Lights, Limo tints on boot and Midnight tint on rear windows, Kenwood screen with Garmin nav, Rear cameras, D4 Steering wheel with flappy paddles, T-max split charge system, Tree sliders, Prospeed roof rack & Ladder, Alisport fast road inter cooler,
Massey Ferguson 35x
Sankey Narrow Track Camping Trailer (Gone but to a great home)
Last edited by sailorboi on 14th Jun 2014 8:24 pm. Edited 1 time in total
14th Jun 2014 8:02 pm
Arlo
Member Since: 03 Dec 2013
Location: Bremen
Posts: 89
Quote:
Then using some lengths of firewood timer I made a bender Very Happy , I have a fairly hefty bending press, but the sheets too wide at 1.6m
You are kidding me, aren't you?
I had to go some miles to pick the 600kg mashine up and got the road back from Düsseldorf back to Bremen!
And you just bended it between roof woods?
Rivets are from a fixing company near my office, the rivet is sealed, the mandrel is Steel but the body Aluminium, they are 4.8mm x 9.5mm that gives the ideal grip range of 3.5-5.0mm just what I needed
don that before today as well but once you go up is size Home of RLD Hidden winch mounts Spare wheel Locks Trailer Body Fabrication ray@rld-tech.co.uk D3/4 sump plates MY 14 sump plates and the Discovery Sport wheel protectors Discovery 5 wheel locks
more Helsport tents and other things for camping Law of Mechanical Repair:
"After your hands are coated with grease, your nose will begin to itch and you'll have to pee!"
14th Jun 2014 8:25 pm
sailorboi
Member Since: 26 Oct 2012
Location: Bristol
Posts: 2021
What thickness ali sheet and steel box section are you using??07 Java Black TD V6 D3, EGRs Blanked, Tow bar, Full dog guard & divider, LED Spots , DRLs, GG ATs, RLD Sump guard, RLD Spare Wheel Protector, D4 LED Rear Lights, Limo tints on boot and Midnight tint on rear windows, Kenwood screen with Garmin nav, Rear cameras, D4 Steering wheel with flappy paddles, T-max split charge system, Tree sliders, Prospeed roof rack & Ladder, Alisport fast road inter cooler,
Massey Ferguson 35x
Sankey Narrow Track Camping Trailer (Gone but to a great home)
14th Jun 2014 8:28 pm
Arlo
Member Since: 03 Dec 2013
Location: Bremen
Posts: 89
RLD wrote:
done that before today as well but once you go up is size
2 lots of box, 30x30x3mm for the main frame, the rails that that sit on the trailer, verticals and upper rails , then 20x20x2mm box for infill crow members and braces to keep the weight down
The sheets are 19 gauge, circa 1mm, hence I could bend it do easy, no real structural element in the sheet, and it got a deal on "damaged" stock at £20 per 2.5M x 1.25M sheet Altox GSM FBH controller thread
IID Pro MV License - D3, D4 & RRS - Enabling, Updates, D4 & RRS Timed / Remote Climate, D4 Bluetooth fitting
PM me for details
Owner of the original "Beanie" grille
D4 & RRS style D3 grilles made to order
done that before today as well but once you go up is size
Very strange British humor.
No just Rays typing, what he's saying is, he's bent sheet the way I did, but as the thickness increases you'll not be able to, Rays POD is built for 5mm think sheet, so no hand bending Altox GSM FBH controller thread
IID Pro MV License - D3, D4 & RRS - Enabling, Updates, D4 & RRS Timed / Remote Climate, D4 Bluetooth fitting
PM me for details
Owner of the original "Beanie" grille
D4 & RRS style D3 grilles made to order
14th Jun 2014 8:51 pm
sailorboi
Member Since: 26 Oct 2012
Location: Bristol
Posts: 2021
beanie wrote:
2 lots of box, 30x30x3mm for the main frame, the rails that that sit on the trailer, verticals and upper rails , then 20x20x2mm box for infill crow members and braces to keep the weight down
The sheets are 19 gauge, circa 1mm, hence I could bend it do easy, no real structural element in the sheet, and it got a deal on "damaged" stock at £20 per 2.5M x 1.25M sheet
3mm ok I going to use 2mm to keep the weight down and that 0.7mm sheet too already colour coded 07 Java Black TD V6 D3, EGRs Blanked, Tow bar, Full dog guard & divider, LED Spots , DRLs, GG ATs, RLD Sump guard, RLD Spare Wheel Protector, D4 LED Rear Lights, Limo tints on boot and Midnight tint on rear windows, Kenwood screen with Garmin nav, Rear cameras, D4 Steering wheel with flappy paddles, T-max split charge system, Tree sliders, Prospeed roof rack & Ladder, Alisport fast road inter cooler,
Massey Ferguson 35x
Sankey Narrow Track Camping Trailer (Gone but to a great home)
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, I have a fairly hefty bending press, but the sheets too wide at 1.6m
I am so so itching to get back home now and start welding some box section together..... hurry up July 18th ish 
