My overland RTW trailer project...

[Baron Bolton]

Having come about 23,000 miles from England, across Europe, Kazakhstan, Mongolia and Russia, I'm now just North of San Francisco (Vallejo).

For some reason I've bought an old R100GS, and my girlfriend and I are trading Honda dirtbikes for a two up machine, and I've got my heart set on making a trailer for our gear.

There seems to be no shortage of fellow motorcyclists keen to tell me this is a dumb ass idea, and I expect they're right. But some things you have to learn for yourself, and I've made up my mind this is what I want to do.

...so really I'm asking for help of some sort.

I think the best idea is to get hold of a carcass of some sort to base the thing on. Maybe a very small car trailer or something similar.
Other option would be to build the whole thing from scratch, wheels, axles, suspension, chassis etc
Harbour Freight seems a good place to source parts like this from, but maybe there are better places?

Is there anyone locally that might be able to help in any way? I can just about MIG and TIG weld (really badly), but I've not really got access to any workshop or anything. Does anyone have any materials, parts, lights, electrics that I might buy, to save on shop prices?

I'll leave it there for now, thanks in advance.

[larryboy]

You're more than welcome to build it here at my place just south of Sacramento. We've got all of the places for parts nearby.
I've got all the tools and welder(I weld/wrench for a living). I'm within a week or so of ordering a die for my tube bender so I can bend .75" square tube, I've got a die to bend 1.75" round already.

Figure out a hitch first.

Have you considered a sidecar instead?

[ADVMindset]

I think that Your mention of Harbor Freight is possibly the way to go if You don't have the time or place to construct something. Their trailers are bolt together and are fairly lightweight. You can modify to suit Your needs !
Good Luck !
btw, where are You headed from Cali ?

[TUCKERS]

I'd be very particular about which wheel/wheels the trailer had. Some of the Harbor Freight wheels have a very small diameter. Will you want spare wheels or flat fixer capability? Will the trailer want to be lockable?
Just a couple of thoughts.

[Baron Bolton]

Well that was a much more positive response than I was expecting!

Larryboy, that is extremely kind of you, and I'll almost certainly take you up on that offer. Any chance you could pm/email me with some contact info?
Guess about an hours ride from Vallejo to you?

I did briefly consider a sidecar (my Dad had one for 15 years or so), but I've tried one and found it a real challenge to control with any predictability.
Plus a trailer can be quickly de-hitched and you've got a proper bike, a luxury that you don't have with a sidecar.

From California, we're heading down the coast to the Mex border. Then probably Baja, which may be interesting with a trailer!? Then eventually Argentina, before Africa/Asia and home.

I have thought about wheels, and figured a larger size would be sensible. Also tire availability in other countries is likely to be important, but no idea how I'll find that kind of info from here. I'll certainly carry puncture fix kit; had over 30 punctures so far on the trip!

Does anyone know what size ball hitch I should be looking at, seems you can get 1 7/8" and 2".
It would be good if the trailer could be towed by a car I guess, so I'll measure one of them.

Certainly a lockable trailer, very important.

[airborndad]

I would use motorcycle tires/rims preferably the same size as the front on the bike that your using- so you'll have spares for the bike -- carry the same size tubes + bigger wheels dont fall into holes and shoot the trailer in the air- you know they are road rated and how long they will last - easier to find replacements - I would avoid the Harbor freight stuff some is good or at least good enough and some is crap.

Just my opinion
Good luck
I could help with MIG and fabrication (expert on both) but I rarely have time and I'm pretty far away + looks like you have something closer
If its a 1-2 day build I can do it . I'm VERY limited on garage space so a weekend in the driveway is doable
Got drawings?

[goodtimes]

Gabe --

Personally, I don't think it is a crazy idea, but it will saddle you with some serious limitations. I don't know your riding style, or the type of terrain you will be traversing, but if you are seeking out tight, rough trails, a trailer will make things, uh, *interesting*, to say the least. If you are sticking to actual roads, I don't think it is nearly as big of a liability. Hell, mountain bikers have been using them for years.

I suggest you reconsider anything coming out of Harbor Freight. In my experience, if it has moving parts and needs to put up with anything more than light duty, occasional use, Harbor Freight *anything* will simply create headaches. I've been there, I've done that. This trailer is not something you want to cut corners on.

While they have not (to my knowledge) built any sort of motorcycle trailer (other than one custom unit to haul motorcycles . . . ), the guys at Adventure Trailers have a ton of experience building trailers for off road use. These are high end, high quality trailers with suspensions that actually *work*. They are also great guys (I've shared more than one beer and campfire with them), who would probably be willing discuss your ideas with you, and give you feedback based on 'real world' experience in trailer design and testing. They'd probably build you a trailer if you wanted. Their stuff is not cheap -- but you wouldn't be getting a cobbled together POS Harbor Fright (sic) trailer either. (note -- I don't work there, nor do I have any financial tie to their business)

Regardless, it will be interesting to see what you come up with.

Good Luck!

[Baron Bolton]

Thanks again.

One thing I have thought is this: I can have my UK motorcycle in the USA for up to a year, and I've been here 4 months so far. So I think I'll leave the Honda here while I take the BMW and trailer south. That way I can come back and swap if I want to. Also I know an amazing shipping company (Aladdin freight) that will ship bikes here to UK for 450 bucks.

I did think of the using motorcycle wheels/tires on the trailer, but this makes such a difference to costs and fabrication, that I think it's prohibitive.

I figure the project can cost as little as about $280, and as much as about $2500, well really, anything you want.
I need to keep it low, and I'm aware of the limitations this in itself will impose, but that's the way have to do it.
I guess BMW wheels would be a lot, and then there's the lengthy and complicated process of mounting them to axles etc.

As far as the limitations of trailer and terrain. I'm now riding with my girlfriend, who is no motocross racer. So rding with her I would be taking thing a lot easier that I have previously. So I think it makes little difference that we're on a big bike with trailer. But I may be wrong.

The harbor freight opinions are a bit of a worry. I just got back from there and it seems this is the easiest and cheapest way of doing the project.
They have a small basic trailer for $170, that I could modify pretty easily.
See below;


I can't possibly get the parts to build something cheaper than this; 2 8" wheels, 2 hubs, leaf spring suspension, axle, hitch assembly, electrics, lights.
This is new and ready to register, something that may be a lot harder if I was to build something from scratch. This I can register, then modify to my needs.

I think I'd cut it down to be a lot narrower, taper the front, and build an aluminum lockable enclosure to bolt on top.

The Adventure Trailer stuff looks great, good quality overland spec stuff, but it's cripplingly expensive. I've been away from home 9 months, and still haven't yet spent nearly as much as the price of their cheapest product!

Am I a complete muppet thinking about buying harbor freight. Can it really be that bad?

[RiverRat]

Ratman might have some insight on trailers.

[larryboy]

Originally Posted by Baron Bolton

Am I a complete muppet thinking about buying harbor freight. Can it really be that bad?

It's not that bad, we can throw in a few gussets and beef it up during the narrowing. There is a metals thirft store nearby that has odds and ends of aluminum for your enclosure.

Sending you a PM...

[goodtimes]

Originally Posted by Baron Bolton

Am I a complete muppet thinking about buying harbor freight. Can it really be that bad?

In my opinion, YES!!!!!!!!

You mentioned that you can't buy the components to build it as cheap as you can buy that trailer. Well, there is a reason for that (and volume isn't it!)!

The things that would concern me about that trailer are the suspension and the tire size. Leaf springs that short (eye to eye) are going to be way to stiff. Couple that with no damping (shocks), that thing will be all over the place once you get off the nicest of roads. Substituting a longer spring (say, 36" eye to eye) and a shock with light (loose?) damping, would make a big difference.

The tires are so short that the angle of incidence will be HUGE on anything bigger than a golf ball. This will again, just like the suspension, throw the trailer all over the place if you are going faster than a crawl. I'd go with the tallest tire you can get (if it is even an option).

The frame isn't so much of a concern -- you're going to cut it down anyway, and I assume weld it all together so the bolts don't rattle out. But man, that suspension coupled with short tires are going to make it rough.

For the box (no matter what you use as a base), you might check the local Craigslist for used truck tool boxes . . . can be had in aluminum, locking, and reasonable size. Even when new, they are only ~$200 bucks or so from the local Home Depot or Lowes.

Good luck!

[airborndad]

Originally Posted by Baron Bolton

Thanks again.

I figure the project can cost as little as about $280, and as much as about $2500, well really, anything you want.
I need to keep it low, and I'm aware of the limitations this in itself will impose, but that's the way have to do it.
I guess BMW wheels would be a lot, and then there's the lengthy and complicated process of mounting them to axles etc.


The harbor freight opinions are a bit of a worry. I just got back from there and it seems this is the easiest and cheapest way of doing the project.
They have a small basic trailer for $170, that I could modify pretty easily.
See below;


I can't possibly get the parts to build something cheaper than this; 2 8" wheels, 2 hubs, leaf spring suspension, axle, hitch assembly, electrics, lights.
This is new and ready to register, something that may be a lot harder if I was to build something from scratch. This I can register, then modify to my needs.

I think I'd cut it down to be a lot narrower, taper the front, and build an aluminum lockable enclosure to bolt on top.

Am I a complete muppet thinking about buying harbor freight. Can it really be that bad?

IF you decide to go this route put larger diameter wheels/tires - buy a spare preferably 2 spares.
Then bring it by my place and I can make it narrower and weld it all together -- or larryboys


p.s. just saw it and I agree 100% with goodtimes post

[RiverRat]

To keep the weight down you want to use motorcycle wheels.

[Baron Bolton]

Given the unknowns of this, and the fact I've no idea if it'll be a long term arrangement, I'm going to go cheap the whole way and see if it's any good for me.

So armed with a 20% off coupon, I'll hear to Harbor Freight and get this crappy chinese trailer, and chop it down. Maybe lose one of the leaf springs to give more flex.
Try the 8" wheels, and if they're crap, then up them a couple sizes.

Next thing I need to figure out is a swivel hitch. Off the shelf purpose made things are about 180 bucks. I think i really do need something to allow the bike to lean right over without fouling the 25 degrees allowed by a std ball joint hitch.
Any ideas?

Also the wiring...
Is it going to mess with the relays if I tap into the wiring and siphon off the current/signal needed to power the trailer indicators?

Many thanks

[TUCKERS]

So there you have it Gabe, it's all about the wheels. Those little tires won't last long on rough paved roads. If you stick to the main road in Baja it's nicely paved for the most part.

I'd be looking at using a car wheel, tubeless, with available rim size for fresh tires. Not too heavy if you get alloy rim.

There are some one wheeled trailers for motorbikes that are pretty cool, perhaps you could make one.

Look online for a 'camping' trailer, there are even ones for motos that you can convert to a sleeper.

Look on the Goldwing sites, a lot of those guys pull trailers. Instead of trying to re-invent the wheel you could learn from them.