Trailer

This is a really simple design based off the trailer in Barrys video where the craft can be pulled on with or without power.

Fabrication

[Click on the pics for bigger versions]

The rollers are simple keel rollers and the smaller ones where there craft rests during transit provide positive side-to-side location.

    • axle is a dexter #8 axle starting at 22.5degrees down with 600lb rubbers so the load is very soft for the 350lb craft load.
    • wheels are galvanized 8" rims with Loadstar C-rated 16.5x8 tires from RecStuff.com.
    • winch is the lightest fastest one I could find (for PWC from West Marine - 400lb
    • jockey wheel again is the lightest I could find.

The total weight of the trailer is very light - the 3x1.5x3/16 C-channel is about 4.1lb per foot and there is about 23 feet (94lb), a bit for the fenders (1.5"x0.120 angle), about 6lb for the winch post, 4lb for the wheel, 2lb for winch etc.

I just need to finish prepping it (angle grinder with flap-discs and sanding discs) and paint it with the ZRC cold-galvanizing paint. I wonder if I could've bought this stuff cold-rolled and saved the effort of removing the mill scale. I can't remove it all even sanding it as there are pits holding a bit left on there. Still I got a quote of $1150 to hot-dip it and they still wanted it prepped before!! Since I had most of a gallon left of the ZRC it made more sense to do it myself. The ZRC is nice in that it is self-healing to some degree.

I was originally going to fabricate using my TIG welder but decided to get a MIG too. I went for the Hobart Handler 187 and some C-25 gas (Argon with 25% CO2) and am extremely happy with it!! Does a quick job with the 3/16 mild steel bits.

I had to extend the width of where the axle mounts on the frame. I wanted the frame to match the skid rails of the craft so it is 39.5" wide but needed the wheels pretty far set out as the craft has a wide plow-plane. The overhang I needed was too much for Dexter to certify at its capacity (600lb) given that the tubing they use for these lightweight axles (#8 series) is only 1.75" square so I extended 3" each side.

You can see in the mounted pic on right some slanted washers I had to make. The c-channel edges are not straight 3/16" thick - they slope at 10deg to the edge. Good for reducing weight - bad for bolting to. I decided to not use stainless here and for the coupler - not like me! I went with grade-8 7/16 bolts for the extra strength. This trailer will hopefully never be submerged (although it can handle it fine with the ez-lube sealed bearings and no-tube design).

The light bar is just a length of 1x6 vinyl fence railing from a ranch supply store. Super light, durable and hollow to keep the wiring tidy. The bar also doubles up as a stand for placing under the bow to insect the underside (see aluminum bracket).

Actual Weight

By weighing under each wheel I summed up the weight as follows:

Without craft

Left 75lb Right 85lb Jack: 65lb

So the total weight of the complete trailer is 225lb including the 16.5x6.5 wheels, hitch, winch etc.

With craft

Left 245lb Right 255lb Jack 70lb

Total laden weight of 570lb

This puts the craft (without fuel tank) at 345lb - right on target! Happy.

Loading Techniques

There are two basic techniques for getting the craft on and off. First is like in Barrys video where the craft is left on hover and driven/dragged up onto the rollers while the trailer is still attached to the car. This needs some good alignment unlike the technique below.

The other technique is where you prop up the front of the craft with a stick and slide the trailer underneath (not attached to car). Line up the rollers, attach winch and as the trailer lifts up and slides under the craft eventually the craft tips up and rolls onto the trailer and the craft and trailer front comes back down. Pretty easy actually. It is made easier by slinging the three or so transit straps around the skirt when its propped up (need these anyways since the skirt will drag on the ground without.