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Old 04-14-2013, 12:40 PM   #61
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I made up a pair of brackets to attach the tub end of the tailgate cables to:





The fiberglass end panel is plenty strong enough to support weight on the tailgate, here's the 225-lb gorilla test:



The aftermarket fiberglass tailgate creaked a little under the weight of this test, but the tub was solid.

There are more photos of the tailgate installation in the main build thread at the Trailer Adventuring forum: Fiberglass M416/M100 Military-style Trailer Tub Kit

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Old 04-16-2013, 08:00 AM   #62
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I tried out an under-$5 Harbor Freight camo tarp for size:



Looks like once I get some bows and some tie-down hooks installed, this tarp will work out pretty well. It's a pretty flimsy tarp, but for people on a budget, it could do just fine until a more substantial cover could be afforded.

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Old 04-16-2013, 04:36 PM   #63
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Before the tub is bolted on, it's easier to do some of the hardware tasks I've got planned for the frame. This morning

I mounted a pair of stabilizer jacks on the rear. I wanted to angle them out at the rear corners for best stability, so I made up some brackets out of steel angle to mount the jacks to:



I welded nuts to the brackets to make it easy to install/remove the jacks from underneath.

Here's how they look when they're deployed:



And stowed:

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Old 04-16-2013, 05:05 PM   #64
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Looking good as always.
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Old 04-17-2013, 05:22 PM   #65
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Today I took the tub to the tonneau manufacturer's shop; they made a prototype tonneau to fit it.

Here are a few photos of the tonneau cover work in progress. Didn't even have to unload the tub from my truck, just backed the whole thing into their shop.



I'll post photos of the completed and installed tonneau tomorrow.
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Old 04-18-2013, 07:12 AM   #66
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Here are some photos of the installed tonneau. Also on the front I've temporarily clamped the parts from a Harbor Freight cargo rack in place.







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Old 04-18-2013, 07:14 AM   #67
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A few more photos, showing the tonneau unsnapped.



There's a tailgate bar which supports the cover across the top of the tailgate, and provides a weatherstrip seal for the top of the tailgate.



That bar slips right out when full access to the tailgate opening is required.



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Old 04-18-2013, 10:14 AM   #68
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Old 04-18-2013, 12:02 PM   #69
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Today I installed the lights. Rather than using the lights that came with the Harbor Freight frame kit, I installed tail lights that are correct for the M416A1:



And although the original military trailers had reflectors instead of side marker lights, I've installed military-style side markers to comply with lighting regulations in my state:

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Old 04-18-2013, 01:19 PM   #70
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Next up: replacing the cardboard mockup fender with actual fenders. I've got a pair of 13"-wide round M100 style fenders, and also in this photo you can see the beginnings of the 13"-wide M416-style fenders I'm making.

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Old 04-19-2013, 08:44 AM   #71
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Looking great and giving me ideas for my build
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Old 04-19-2013, 09:02 AM   #72
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I received a message from the forum that my PM inbox is full. I don't have enough inbox space for all the PM's I receive, so if anyone wants to contact me privately, they can send me an email, just click on my user ID and select "send email" instead of "send private message". Sorry about that but I don't have time to manage all the PM's I get, email is much easier for me.
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Old 04-19-2013, 10:58 AM   #73
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Got the fenders finished up and bolted on this morning. First some photos of the M416-style wide fenders:







And got the front rack bolted on this morning, although it needs a few shims to perfectly level it out. In these photos the coupler is the HF ball coupler that comes with the trailer frame kit, but converted to a receiver mount.
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Old 04-19-2013, 10:59 AM   #74
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And some photos of the M100-style wide fenders:







In these photos the coupler in the front receiver is a TSC 3-Axis.
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Old 04-19-2013, 10:59 AM   #75
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Comparison... which style do you like best - M100 round fenders or M416 angular fenders?

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Old 04-19-2013, 06:00 PM   #76
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Hard to say, they both look great.... I guess I would go with squared over rounded. More utility....gives you a place to set your cold beer.
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Old 04-19-2013, 06:10 PM   #77
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Hard to say, they both look great.... I guess I would go with squared over rounded. More utility....gives you a place to set your cold beer.
And if you need even more space to put down drinks or whatever, the angular fenders make a nice place to attach a table bracket like the one available from Compact Camping (Camping Box Side Table Compact Camping Trailers Table Explorer Box) .

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Old 04-19-2013, 09:07 PM   #78
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Comparison... which style do you like best - M100 round fenders or M416 angular fenders?
I like the flat vs. the round fender. To me the round says semi truck and the flat says utility. You could mount a jerry can on each for example.
Great work.
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Old 04-19-2013, 09:27 PM   #79
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And if you need even more space to put down drinks or whatever, the angular fenders make a nice place to attach a table bracket like the one available from Compact Camping (Camping Box Side Table Compact Camping Trailers Table Explorer Box) .

This
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Old 04-21-2013, 04:16 PM   #80
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Today I got the floor installed into the tub.





The floor is 1/2" plywood. The wood will be sealed on all sides with a paintable wood sealer, and when I do the final installation of the floor, the joints between the side/end panels and the floor with be sealed with automotive seam sealer (could also be done with paintable latex caulk), and the final finish on the inside will be bed liner color-matched to the exterior paint.

There are lots more photos of the floor build/install in the main build thread in the Trailer Adventuring Forum: Fiberglass M416/M100 Military-style Trailer Tub Kit
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Old 04-21-2013, 07:35 PM   #81
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great progress.....

I recognize the potential utility of the flat fenders.....but round-fenders are what I like.

Just amazing to see your careful steps here. Did you do a metal tub trailer project here a few years ago with a Jeep tail gate?
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Old 04-21-2013, 07:45 PM   #82
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great progress.....

I recognize the potential utility of the flat fenders.....but round-fenders are what I like.

Just amazing to see your careful steps here. Did you do a metal tub trailer project here a few years ago with a Jeep tail gate?
I've done three trailer projects... left to right, the fiberglass Jeep-tub project that became the Dinoot kit, the current military project, and my all-metal Jeep-tub trailer made from the back halves of an LJ and a YJ:

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Old 04-22-2013, 11:44 PM   #83
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This is really neat!
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Old 04-23-2013, 02:16 PM   #84
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Before I disassemble the trailer to begin the painting process, I'm trying to finalize decals for it. I plan a military theme, but I'm not going to strictly adhere to military standards. I'm going to paint the tub olive drab, and I'll do the inside in color-matched olive drab bed liner. Here's what I'm thinking for the decals:



I've printed out a test set and taped the printouts in place to see what everything looks like. The decals would be white on the olive drab tub, but since I'm testing them on the unpainted white tub, some of them I printed in black.

Sides:



Tailgate:



A reproduction M416 data plate:



What do you think? Any suggestions for changes/improvements?
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Old 04-24-2013, 05:54 AM   #85
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I finished up the mounting of the Harbor Freight cargo rack on the tongue, now it's properly leveled and secured. Also found a nice cargo box at Walmart for $40, it's a pretty good fit along with two NOS military gas cans:





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Old 04-24-2013, 05:56 AM   #86
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Before I disassemble the trailer to begin the painting process, I'm trying to finalize decals for it. I plan a military theme, but I'm not going to strictly adhere to military standards. I'm going to paint the tub olive drab, and I'll do the inside in color-matched olive drab bed liner. Here's what I'm thinking for the decals:



I've printed out a test set and taped the printouts in place to see what everything looks like. The decals would be white on the olive drab tub, but since I'm testing them on the unpainted white tub, some of them I printed in black.

Sides:



Tailgate:



A reproduction M416 data plate:



What do you guys think? Any suggestions for changes/improvements?
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Old 04-24-2013, 09:13 AM   #87
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Hurry and get this into production! It looks fantastic! I also really dig the flat fenders more than round.
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Old 04-24-2013, 07:20 PM   #88
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Hurry and get this into production! It looks fantastic! I also really dig the flat fenders more than round.
Thanks!

Discussions with a company that wants to bring this kit to market are proceeding very well. They're targeting sometime this summer for a release date if all goes according to plan.

Not sure what they'll do about fenders .
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Old 04-25-2013, 06:23 AM   #89
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I found a couple of original military trailers on sale on eBay this week, and the photos were similar angles to ones I took of this project, so I did up a comparison:



My project has Jeep-sized tires which are larger and wider than the tires on the original trailers, so I've got wider fenders in both the M100 and M416 styles to cover those tires. Another difference you can spot is the lip on the tub projects outward on the original tub, on mine it projects inward - I did this to make the outside look nicer, to provide for internal clamping points for things like the tonneau cover, and to keep the overall width of the tub just under 48" so a hard cover could be DIY-built from a single sheet of plywood. One other small difference is that the fiberglass tub is almost 2" taller to increase the cargo capacity below the top rim of the tub (and below any hard covers that might go on there).
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Old 04-26-2013, 12:44 PM   #90
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I hope you can find someone to pick this up and start making it. I wonder what the retail cost might end up being.

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