My offroad "Bos Pandok" caravan built





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  1. #1
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    Default My offroad "Bos Pandok" caravan built

    As I did not have a big budget startng this project, I guess I did this project with materials I already had and the rest easy to find. fabrication i had do myself with the basic tools i have. My basic tools.... arc welder, grinder, drill, skillsaw and jigsaw. I started off with a multipurpose trailer I already owned. I installed new 1.2ton leaves and a new axle that I made up myself from 60mm steam pipe 5mm waĺl thickness and BMW 5 stud hubs (front struts). the floor of the caravan is 18mm shutterply. Frame I used 25mm aluminium square tubing 2mm wall thickness (bought). Outside skin 1.2mm aluminium sheeting (bought). The design is something I worked out in my head and just did as I worked it out in my mind. Here are a few pics off the start and framework. (Used corner profile fittings to join tubing).
    Last edited by Disa; 2018/06/16 at 11:36 PM.

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  3. #2
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    Default Re: My offroad "Bos Pandok" caravan built

    Here is some pics off the start
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    Default Re: My offroad "Bos Pandok" caravan built

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    Default Re: My offroad "Bos Pandok" caravan built

    With your wheels so far back it will tow well but keeping nose weight below 100kg might be interesting. The main focus in building a caravan and especially one that has to come in waay below 750kg is to build in lightness. You need to come in at 600kg to have a 150kg payload for all your kit that you want to take along, not an easy task. Rethink using that heavy wooden door for a lighter sandwich construction.

    Good luck.
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    Default Re: My offroad "Bos Pandok" caravan built

    Quote Originally Posted by hbannink View Post
    With your wheels so far back it will tow well but keeping nose weight below 100kg might be interesting. The main focus in building a caravan and especially one that has to come in waay below 750kg is to build in lightness. You need to come in at 600kg to have a 150kg payload for all your kit that you want to take along, not an easy task. Rethink using that heavy wooden door for a lighter sandwich construction.

    Good luck.
    Thanks for the reply. The window and door is made off aluminium. The axle so far back is because tha caravan sleeps 2. We are a family of 4. I plan to hinge a Echo 1.4m roortop tent on the back of the caravan for the kids. Also a spare wheel and 4 x 20l jerry cans.
    Last edited by Disa; 2018/06/17 at 01:07 AM.
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    Default Re: My offroad "Bos Pandok" caravan built

    Does anyone have experiance or now the road forward with regestration. As I am building the caravan on an allready registeted "Kokerbak" trailer.... can I use it as is?
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    Default Re: My offroad "Bos Pandok" caravan built

    Lekke Disa sterkte ek hou jou vordering dop

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    Default Re: My offroad "Bos Pandok" caravan built

    Quote Originally Posted by Disa View Post
    Does anyone have experiance or now the road forward with regestration. As I am building the caravan on an allready registeted "Kokerbak" trailer.... can I use it as is?
    Just do a search there is a recent trailer build the guy was also using a kokerbak
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    Default Re: My offroad "Bos Pandok" caravan built

    Well done Disa, moving the goal posts of DIY!
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    Default Re: My offroad "Bos Pandok" caravan built

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    I'm planning to insulate the walls with 22mm Isofirm offcuts i have left after doing the ceilings of the bedrooms in my house. I've installed doors covering the opening for the side kitchen and the slide out fridge.
    Last edited by Disa; 2018/06/17 at 08:39 PM.
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  13. #11
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    Default Re: My offroad "Bos Pandok" caravan built

    I will not have water tanks and waste water tanks installed. I plan to have a portapotty with Biodegradable chemicals. I will have 2 x 10l water cans under the little sink. One can for clean fresh water with submersible pump (12v) and one empty can for waste from sink. I bought a National luna battery power unit with built in solinoid. I will run 5 led lights and the submersible pump off the deap cycle battery. Try to keep it simple and not to expensive. Also will run a National luna 90l fridge freezer of battery.
    Last edited by Disa; 2018/06/19 at 06:24 PM.
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    Default Re: My offroad "Bos Pandok" caravan built

    "25mm aluminium square tubing 2mm wall thickness "

    Ive always had this idea in mind for the basic frame.
    Why not, at my age the trailer doesnt have to last forever.
    If you live each day as if it was your last, someday you'll most certainly be right. SJ

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    Default Re: My offroad "Bos Pandok" caravan built

    Quote Originally Posted by Damdan View Post
    "25mm aluminium square tubing 2mm wall thickness "

    Ive always had this idea in mind for the basic frame.
    Why not, at my age the trailer doesnt have to last forever.
    Im making use of a Sikaflex product to glue panels to tubing. Edges are covered with 25mm aluminium angle with ss rivets. Try to keep it as light as possible
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  16. #14
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    Default Re: My offroad "Bos Pandok" caravan built

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    Getting there.

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    Default Re: My offroad "Bos Pandok" caravan built

    the 25mm alu tubing connected with Connect-IT pieces? Or am I seeing wrong?

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    Default Re: My offroad "Bos Pandok" caravan built

    I have the greatest respect for these okes that "build their own"

    Well done...enjoy your own...
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    Default Re: My offroad "Bos Pandok" caravan built

    Quote Originally Posted by Rustie View Post
    the 25mm alu tubing connected with Connect-IT pieces? Or am I seeing wrong?

    Yes. I bought them at Mica. They had to br grinded alittle as they are made for tubing with 1.6mm side wall. I used 2mm. I also screwed then together with normal self drilling screws. I guess time will tell to how well it will last/keep up.....
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  20. #18
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    Default Re: My offroad "Bos Pandok" caravan built

    Quote Originally Posted by Dungbeetle View Post
    I have the greatest respect for these okes that "build their own"

    Well done...enjoy your own...

    Thanks.... At the end of the day we do with the money available and for it to work for your own purpose. Its standard with no frills but affordable and lots of fun.
    Last edited by Disa; 2018/06/18 at 06:12 PM.
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  21. #19
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    Default Re: My offroad "Bos Pandok" caravan built

    I built a roofrack with the connectit fittings
    It has thusfar lasted over 2 years with a nuber if 4x4 trips with a rooftop tent strapped to it

    Next project trailer like yours

    Q:where did you buy the aluminium sheeting?
    Quote Originally Posted by Disa View Post
    Yes. I bought them at Mica. They had to br grinded alittle as they are made for tubing with 1.6mm side wall. I used 2mm. I also screwed then together with normal self drilling screws. I guess time will tell to how well it will last/keep up.....
    Wolverine : 93' Range Rover Classic 3.9L EFI

  22. #20
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    Default Re: My offroad "Bos Pandok" caravan built

    Quote Originally Posted by whosthejman View Post
    I built a roofrack with the connectit fittings
    It has thusfar lasted over 2 years with a nuber if 4x4 trips with a rooftop tent strapped to it

    Next project trailer like yours

    Q:where did you buy the aluminium sheeting?
    Im in Cape Town. I bought it at Non ferrous metals 114 Voortrekker road Salt River.
    '16 BMW X5 3.0D X-drive
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