The Harbor Freight Haul-Master...
The Harbor Freight Haul-Master 1,720-pound-capacity Super Duty 48x96-inch utility trailer was selected as the base for this off-road trailer project. It features 12-inch, five-lug wheels and pneumatic tires and is constructed from 2x4-inch steel C-channel.
I have to admit, I've caught the off-road trailer bug. Maybe it's because I like to camp in comfort and can never fit all of my gear. Or maybe I bring too much gear in the first place. Either way, I've been bit, and an off-road trailer build is underway.
As with any project, before starting in to this off-road trailer build I ran down a checklist of questions to make sure I'd be satisfied with the end product. First, why do I need a trailer? That's an easy one – to haul more gear to and from base camps. How big of a trailer do I need? The way I see it – why tow a trailer that doesn't fit everything you want to bring?
I made up a couple simple...
I made up a couple simple sketches to get an idea on some of the features I'd like include in the off-road trailer build. Note that I am not an artist but a writer so please save any judgment. As you can see I'd like to create an elevated rack area so a rooftop tent can be mounted atop the trailer.
Be careful about building too small or too big though. The 4x8-foot size might not be for everyone but it would allow me to fit a motorcycle or quad should the need arise. Harbor Freight offers utility trailers in a variety of sizes and capacities, including a 3x4-foot mini utility and a 4x8-foot foldable trailer. Wheel size is also important. The 4x8-foot trailer is offered with 4-lug, 8-inch or 5-lug, 12-inch wheels. Knowing I'd likely demolish the 8-inch wheels on the first trip out the 12-inch wheels were the way to go. The 12-inch wheels also provide a greater load carrying capacity.
How will I most often use a trailer? Are difficult trails in its future or is it simply destined for mild trails and highway? For now I simply desired a park it and go 'wheeling type of trailer that would hold all the gear I'd need for a long weekend, so the Haul-Master 1,720-pound-capacity 4x8-foot unit looked like the best bet.
This way I can simply fold...
This way I can simply fold out the tent without unloading any gear. The tent could also be transferred to the vehicle roof for trips that don’t require a trailer full of gear. There are many off-road trailer companies that offer awesome pre-built units that feature similar designs. My goal with this off-road trailer build is to obtain some of the great features that these pre-built units possess while keeping to a limited budget.
What gear do I plan to carry in the trailer and how will I pack it? I've rented utility trailers for weekend trips in the past and they usually end up being loaded to the gills with odd shaped items that leave empty pockets of space throughout. This being the case I'll invest in some heavy-duty storage crates such as the Rubbermaid ActionPacker storage bins. Swag Off-Road offers its Baja Bins, which are cool aluminum bracket setups designed to safely stow the 8- and 24-gallon ActionPacker bins pretty much anywhere, so this may be an option. As far as intended gear, camping and cooking supplies for my family and group events will be the regular load. Tools and spare parts will fill the rest of the trailer, as well as a battery-powered Jeep and quad for the kids.
The trailer I decided to use as the base for this off-road trailer project is Harbor Freight's Haul-Master 1,720-pound-capacity Super Duty 48x96-inch utility trailer with 12-inch, five-lug wheels and pneumatic tires (part #94564). It's made from 2x4-inch steel C-channel, uses a 2-inch hitch ball, and is DOT-approved. The trailer also includes a 30-day, 100-percent satisfaction guarantee, which means you can return it to Harbor Freight within 30 days for a full refund or replacement.
My buddy Scott laid out the...
My buddy Scott laid out the 2x4-inch trailer frame sections in the driveway to begin assembly. It isn’t rocket science but it is recommended that you study the provided instructions as we had to back track a few times after our hands got ahead of our brains.
Utility trailers are usually available from most Harbor Freight stores and always available for shipping via the website. This one lists for around $500 but we've seen it on sale for much less. Plus, 20-percent off coupons are widely available in many popular magazines and Sunday newspapers, and are also available for print on the Harbor Freight website.
You'll continue to see more about this 4x8-foot Harbor Freight utility trailer as it's towed to base camps accessible by moderate dirt trails. You can also plan to see the construction of a smaller, more nimble trailer capable of tackling more extreme trails. Check back next month as I finish the base assembly and begin equipping and packing this off-road trailer for its first trip to the dirt.
The trailer bolts together...
The trailer bolts together using the supplied hardware. We made sure the frame sections were truly square by measuring diagonally from each corner before tightening the bolts.
With the front 4x4-foot frame...
With the front 4x4-foot frame section together Scott secured the tongue frame section. The sawhorses proved helpful in saving our backs and knees.
With the tongue section in...
With the tongue section in place we assembled the rear 4x4-foot frame section and joined it to the front half.
The trailer axle and leaf...
The trailer axle and leaf springs were installed using supplied U-bolts and U-bolt plates.
With the trailer back on the...
With the trailer back on the saw horses the fenders were installed.
The leaf springs are short...
The leaf springs are short but are suitable for the 12-inch wheels and tires. One upgrade we may explore is the use of longer/taller springs to fit larger/taller wheels and tires. It would also be nice to have the trailer use the same wheel bolt pattern as the tow vehicle.
The included five-lug hubs...
The included five-lug hubs were installed. Per the instructions we cleaned and repacked the bearings with fresh grease.
This Harbor Freight 1,500-pound-capacity...
This Harbor Freight 1,500-pound-capacity dual wheel swing-back boat trailer jack was the first addition to the trailer. The dual wheels make maneuvering the trailer a cinch and the fold-back design makes it ideal for off-road trailer use.
The Harbor Freight trailer...
The Harbor Freight trailer jack was easily installed using the supplied hardware. When not in use the jack folds up and stows along the trailer tongue frame.
The trailer is designed to...
The trailer is designed to be fit with a 4x8-foot sheet of 3/4-inch plywood. Here the plywood is only set in place. One of the hinged trailer sides (sold separately) is also shown.
The two-inch hitch ball receiver...
The two-inch hitch ball receiver and safety chains were installed at the tongue frame.
This is where we hit our first...
This is where we hit our first snag; the protruding bolts along the top rail of the trailer frame don’t allow the plywood to sit flush on frame. We considered drilling reliefs in the plywood at each bolt location but realized this wouldn’t remedy the problem for the trailer sides, which are designed to sandwich between the trailer frame and plywood and would also require reliefs/holes at the same locations. None of that sounded appealing so I grabbed the grinder and removed enough paint to weld the seams so the bolts could be removed. I ran out of wire and rain was approaching so this corner was left undone. All of the other bolts were removed and retained for future projects.
The fresh weld beads were...
The fresh weld beads were touched with the grinder and quickly hidden with paint. The aforementioned rain was a good excuse for it but my sloppy welding skills were another. To my credit I was dealing with too much wind and flux-core wire – maybe time to invest in a bottle and some screens seeing as I always seem to be welding outdoors.
The fresh weld beads were...
The fresh weld beads were touched with the grinder and quickly hidden with paint. The aforementioned rain was a good excuse for it but my sloppy welding skills were another. To my credit I was dealing with too much wind and flux-core wire – maybe time to invest in a bottle and some screens seeing as I always seem to be welding outdoors.
The Harbor Freight trailer...
The Harbor Freight trailer side kit is going to make this trailer even more useable. Shown left to right is the left trailer side panel, rear trailer side panel/gate, front panel, and right side panel. The side panels are hinged 4-foot sections. Both the side panels and the trailer will be coated with DuraBak before final assembly. By the way, that’s my ’97 Jeep Cherokee four-door in the background. It’s currently 2WD with a thrown rod through the oil pan. It’s soon to be 4WD with a fresh mill; it eagerly awaits my attention.
This is just about my favorite...
This is just about my favorite trailer add-on so far – the Harbor Freight heavy-duty trailer tongue box. It features a locking, notched lid with a gas strut to assist with opening and closing and is ideal for storage and security. It offers 2.8 cubic feet of storage space and will be the perfect place for storing tools and other valuable items.
Some other Harbor Freight...
Some other Harbor Freight add-ons include a tow hook, a large handle hitch pin, a locking hitch pin, and 1/2-inch flush mount D-rings. The D-rings will be secured to the plywood at each corner of the trailer. The tow hook will likely be secured at the rear for situations where the trailer might need some assistance backing up or being pulled back on to the trail.
While the trailer kit incudes...
While the trailer kit incudes a full set of lights and wiring I’ll instead install a set of Harbor Freight’s Haul-Master weatherproof, submersible, 6-inch oval tail/signal/stop lights and submersible 2-inch marker lights. This will ensure continued operation no matter what the trail conditions.