9X5 TRAILER BUILD PLANS – TANDEM AXLE

$19.95

SKU: DIYPLAN9X5-T Category: Print
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Description

DIY TRAILER KITS
9X5 TRAILER BUILD PLANS

TO BE USED AS A GUIDE ONLY!
THIS KIT IS DESIGNED FOR A BRAKED - 1990KG GTM TRAILER
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1. CHASSIS


Lay out the chassis ensuring all corners are smooth and square.

Weld around all joins to prevent water or moisture entering into the RHS.

Use a grinder to smooth of the top welds so that the floor will sit flush.

STEEL REQUIRED: 50mm x 50mm x 2.5mm RHS

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2. SPRINGS


When placing the spring hangers, ensure the centre of the axle group is slightly rearward from the centre of the chassis (100mm). This will ensure correct ball weight when towing.

Different spring sets will have different spring hanger placements.

​For correct spring hanger measurements,
​visit our SPRINGS PAGE

​Remember to only weld down the sides of the spring hangers and never across the drawbar.

NOTE: Always double check your spring measurements with staff before welding.

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WARNING: Welding across RHS creates a weak point.
NEVER weld across a chassis or drawbar.
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3. WIRING TUBES


Weld small RHS tubes for your light wires to run down.

​This prevents wires from hanging and being exposed to the elements.

STEEL REQUIRED: 25mm x 25mm x 1.6mm

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4. DRAWBAR


Measure 450mm from the very front of the chassis.

Tack weld the drawbar onto the chassis to hold it in place.

STEEL REQUIRED: 2x 2000mm x 100mm x 50mm x 3mm RHS

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Bring the 2 ends of the drawbar together ensuring they meet exactly.

Weld along the join. (As pictured).

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Attach the drawbar to the trailer by welding along each side where it meets the chassis.

Ensure there are enough welds to hold the drawbar on strongly as it undergoes a lot of strain.

NEVER weld across the top or bottom of the drawbar as it creates a weak point in the RHS.

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BOTTOM VIEW
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TOP VIEW
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FLIP THE TRAILER

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5. COUPLING PLATE


When positioning the coupling plate, ensure the plate is offset forward to allow room for the coupling bolts.

The coupling bolts should go through the coupling and plate only,
NOT the drawbar RHS.

Weld down each side of the coupling plate only.
NEVER weld across the frawbar.

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6. SAFETY CHAIN


ONLY use rated safety chain (Stamped every few links).

Attach the chain in such a way that no part of the chain will come in contact with the road if the trailer disconnects. (Not pointing down).

At least 50% of the first link must be welded to the trailer (Inside and outside of the link)

CHAIN REQUIRED: 1x 2500KG SAFETY CHAIN

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7. SPARE TYRE MOUNT


Weld a spare wheel mount using angle iron.

​​When mounting the spare tyre, remember to allow room for your jockey wheel handle to spin.

Cross brace the mount back to the trailer chassis to prevent vibration.

Drill a 1/2" hole where required and weld the nut onto the angle iron.

Remember to use a large washer to prevent damaging the rim.

STEEL REQUIRED: 40mm x 40mm x 5mm ANGLE IRON
BOLT AND NUT REQUIRED: 1/2" x 6" BSW

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8. BODY & CORNER PLATES


Before mounting the body, ensure the welds on top of the chassis have been ground down flat so that the body doesn't sit up and leave a big gap.

Tack the body together down the centre joint (from underneath) and ensure it is square.

Place the body onto the chassis and line it up straight.
tack weld each corner into place.

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Tack weld the corner plates into position.

When happy, go over the whole plate, welding it to the body and chassis rail.

Then attach the rest of the body by welding a 50mm stich between the chassis and body every 300mm (As pictured).

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Then weld the floor to the chassis by placing a 30mm stitch every 200mm on each cross member.

Ensure you stitch across the floor join on each cross member.

Only weld to the cross members. Welds to the side rails are not required underneath the trailer.

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ADD YOUR AXLE, HUBS & WHEELS BEFORE INSTALLING YOUR WHEEL GUARDS

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9. WHEEL GUARDS


When installing your wheel guards, it is important to ensure you have enough clearance for the suspension and wheels to move around when driving.

​100mm clearance is required above the wheel to prevent scrubbing.

​also remember the wheel will always travel backwards when the suspension compresses so make sure there is a little bit of extra room between the back of the wheel and the guard.

The front of the guard will generally line up with the front of the spring hanger.

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To weld on the guard, place a tack at front and rear.
Once happy with the placement, add 30mm stitches to the following areas:

5 along top (centre outwards)
1 along chassis (front & rear)
1 on each corner (front & rear)
​1 between corners and chassis (front & rear)

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10. TAIL GATES


Weld the angle iron onto the folded gate using 40mm stitches.
Weld along the top and bottom of the angle iron for added strength.

Next, weld in the tie down rail 120mm from the top or at your desired height.

Weld in a tab between the rail and the tail gate (dead centre) for added strength.

STEEL REQUIRED:
- ROLLED TAIL GATE x2
- 2x 40mm x 40mm x 5mm ANGLE IRON (per gate)
​- 1x TIE DOWN RAIL (per gate)

Tack your hinges approximately 230mm in from the outer edge of the gate. Ensure your gates open & shut nicely before fully welding the hinges into place.

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11. SIDE TIE DOWN RAIL


When placing your side tie down rails, ensure you leave enough room to fully weld around the rail.

Brace the rail to the mud guard or body as needed using flat steel.

STEEL REQUIRED: 25NB TUBE

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12. LIGHT SURROUNDS


Stitch weld the light surrounds onto the bottom of the corner plate ensuring you have left enough room for the tail gate to open & close.

​Slight overhang is normal when placing these surrounds.

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13. TAIL GATE LATCHES


There are many different styles of tailgate latches you can use.

CLICK HERE to see the whole range of TAIL GATE LATCHES

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14. SKID RAILS


Measure and cut your skid rails to suit using angle iron.
Weld them into place from the chassis rails to the guards.

Skid rails will prevent damage to your guards and add structural strength to your trailer.

STEEL REQUIRED: 50mm x 50mm x 2mm ANGLE IRON

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15. PLUG HOLDER


Weld on a plug holder as required

​TIP: You can place the plug holder to keep the jockey wheel handle from falling and hitting the ground when driving over bumps.

STEEL REQUIRED: 50mm x 50mm x 2mm RHS (70mm long)
For a flat plug use 75mm x 50mm x 2mm RHS

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REMEMBER TO PRIME ALL WELDS

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*NOTE: THIS PAGE IS DESIGNED TO BE USED AS A GUIDE ONLY!
ADELAIDE TRAILER SHOP.COM TAKES NO RESPONSIBILITY FOR THE OVERALL PRODUCT BEING BUILT.
​IT IS THE MANUFACTURERS RESPONSIBILITY TO ENSURE THE TRAILER IS BUILT TO STANDARD AS PER VSB1.