Trailer Upgrade to Braked Axle





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  1. #1
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    Default Trailer Upgrade to Braked Axle

    With the change from the Nissan DCab bakkie to the LC Wagon I decided to upgrade the Challenger Trailer. I need to be able to move some weight around.

    In the unbraked form the Tare is 330kg. That leaves loading capacity of 420kg. That will not even carry my 500L water tank.

    This is what I have to work with.

    I did not like the low number plate. The spare at the back is a pain if you have to open the rear often.






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    Kobus

    HDJ81 VX

  2. #2
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    Default Re: Trailer Upgrade to Braked Axle

    I wanted to fit 31x15 tyres. I had to make sure they will fit into the mud guards. It was also important for the width of the new axle.

    First order of business was to remove the old tyres. No Problem.... just deflate and drive over them to break the bead. Like this.



    Not !!! That tyre did not want to move off that rim. I spent many hours that evening to remove one tyre. Next morning I took the other 2 to the tyre works next to the road. They removed them easily.

    I sanded the rims and spray painted them with Rust-Oleum Flat Black.





    Three new 31x15 Tyres.



    I fitted the new tyre to the axle. 100% ! They will work without any adjustments.

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    Kobus

    HDJ81 VX

  3. #3
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    Default Re: Trailer Upgrade to Braked Axle

    This is the old Unbraked Axle. The 8 blade springs should work with the new axle.



    Two bolts and it is out.



    The new Braked Axle. Same width.



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    Kobus

    HDJ81 VX

  4. #4
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    Default Re: Trailer Upgrade to Braked Axle

    This is where the spare should go.



    I also got my new 2000kg Knott Coupler.



    A very ugly mock-up of what I have in mind.



    I had to flip it over ..... but it still needed to be move-able. No problem. Old axle on the roofrack.





    Upside down. Ready for action !

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    Kobus

    HDJ81 VX

  5. #5
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    Default Re: Trailer Upgrade to Braked Axle

    I had to cut everything off.

    Most of the cutting was done with the 115mm grinder with a 1mm cutting disc.



    I got stuck with the old U-Channel. 115mm grinder disk was too small to cut through. Out came the 230mm grinder. If there is one power tool I have a lot of respect for, it is this thing. One wrong move.....





    I survived. I can continue to tell the story.

    Done. Clean bottom.

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    Kobus

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  6. #6
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    Default Re: Trailer Upgrade to Braked Axle

    This needed some upgrade.



    I added some 50x50x3 support.



    New U brackets for springs are in.



    Leaf Spring mounted on new bracket.

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    Last edited by KobusDJ; 2016/07/19 at 11:18 PM.
    Kobus

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  7. #7
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    Default Re: Trailer Upgrade to Braked Axle

    Going back a bit to the old A-Frame. I liked the flat bar support to the U-Channel. My goal is something similar.



    The U-Channel. 38 x 76 x 6



    The base for the Coupler



    Work in progress









    That 40 x 8mm flatbar support.



    New axle temp fitted. I had to flip it over.



    Right side up. Mock-Up no 2. Everything fits in.

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    Kobus

    HDJ81 VX

  8. #8
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    Default Re: Trailer Upgrade to Braked Axle

    Adding some support to the frame.... and the bottom rest fore the spare.



    Some more support. We do not want that frame to twist.



    Mock-Up 3. Chain Tie-Down for the spare.

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    Kobus

    HDJ81 VX

  9. #9
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    Default Re: Trailer Upgrade to Braked Axle

    Flipped over again. I'm getting tired of this. That thing is heavy.

    Welded the bracket for the brake cables to the underside.

    Painted Red-Oxide.



    Springs and Axle mounted again

    Painted Stone Chip.



    The brake cables attached.



    Thanks to Heinz for his help regarding the brakes in this thread. http://www.4x4community.co.za/forum/...de-Help-Needed

    Brakes done.



    Back on its feet. This was the last time. Thanks.



    Red Oxide and Stone Chip done.



    The threaded rod linking the brakes mounted to the coupler.

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    Last edited by KobusDJ; 2016/07/19 at 11:07 PM.
    Kobus

    HDJ81 VX

  10. #10
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    Default Re: Trailer Upgrade to Braked Axle

    Looks great. Is it not going to be a bit nose heavy with the spare in front now ?


    Pajero 2800 - 1999

  11. #11
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    Default Re: Trailer Upgrade to Braked Axle

    @Shane Isuzu - It is a bit heavy but I can still lift it up with one hand. It will hook up to a LC. A bit extra weight will not do it any harm.
    Kobus

    HDJ81 VX

  12. #12
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    Default Re: Trailer Upgrade to Braked Axle

    To be continued ......

    Ek gaan nou slaap.
    Kobus

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  13. #13
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    Default Re: Trailer Upgrade to Braked Axle

    Small items. Sanded and primer.



    Those old branding stickers and yellow reflective tape did not come off easy.



    Morsige werk.





    Every now and then there is a dog ear or tail in a picture. Here is dog.



    Almost ready for paint.



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    Last edited by KobusDJ; 2016/07/20 at 05:54 PM.
    Kobus

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  14. #14
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    Default Re: Trailer Upgrade to Braked Axle

    Some more Red Oxide



    Hond en hond se maatjie is maar altyd daar.



    Stone Chip. I do not have thetools to spray it on. I used those cheap spunge rollers (with the red plastic handles) you buy at Game or BW. It gives a nice uniform ripple effect.

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    Kobus

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  15. #15
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    Default Re: Trailer Upgrade to Braked Axle

    I was looking at Toyota Beige as a final coat.

    Here it is. Toyota Sand Beige 4E9. Discussed here: http://www.4x4community.co.za/forum/...2-Paint-Colour



    I know.... I missed a spot.



    Next day. Touched up all the "missed spots"

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    Kobus

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  16. #16
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    Default Re: Trailer Upgrade to Braked Axle

    This was "black paint day" !

    It got ugly. It looked like the backyard of a spraypainter from a well known East Rand town.

    ............

    Remember those rims with the "Flat Black" paint. I didn't like it. It is not durable... scratch easy. They were lined up for some 2K black with all the other stuff.

    Here it goes.









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    Kobus

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  17. #17
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    Default Re: Trailer Upgrade to Braked Axle

    Almost Done ! This the current status.

    Everything is just put back in place. Nothing bolted down.

    Next is the yellow reflective tape. Then the roofrack, all the hinges and latches and so on. Last the reflectors, lights and wiring.





    From the beginning I only had help from my wife to turn the trailer over a few times. She and the daughter also helped masking everything the day with the black paint. Everything else I did alone.

    I hope to finish in a week. Then I need to sort out the new weight registration with the Dept. of Transport.
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    Kobus

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  18. #18
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    Default Re: Trailer Upgrade to Braked Axle

    Lyk baie netjies!
    2009 Toyota Fortuner 3.0 d-4d 4x2
    Custom off-road trailer with Echo TTT

  19. #19
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    Default Re: Trailer Upgrade to Braked Axle

    Would it have been cost effective to buy a new one rather, sell the original one ?

  20. #20
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    Default Re: Trailer Upgrade to Braked Axle

    @ konstanddp - Thanks

    @NewLandy - It was a load of work but I think it was worth it. New entry level Braked Trailers (+-1350kg GVM ) goes for +R40000-00. I have spend less than one quarter of that. The trailer before the upgrade was not worth much for someone else.
    Last edited by KobusDJ; 2016/07/21 at 07:44 AM.
    Kobus

    HDJ81 VX

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