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For those of us who enjoy outdoor activities, such as boating, riding dirt bikes,
bicycling, or snowmobiling, and own one or more of these “toys”, it’s likely that
you also own an open style trailer to haul them back and forth. The one thing these
activities have in common is that you have to tote along all the accessories. Most
open trailers don’t have adequate storage space, if any, to accommodate the life
jackets, helmets, paddles and gear, not to mention any spare parts or tools you may need.
Staring at my boat trailer sparked an idea for an easy do-it-yourself
solution for all my accessories and spare parts. What about attaching
a utility box to the trailer? The first thing that came to mind was a truck storage box.
In order to achieve a lasting solution, the
truck box needs to be securely attached to the trailer. As you can see from the list of materials, tools you’ll need,
and the all important safety equipment below – the trouble of where and how to
get started on this great do-it-yourself project has all been laid out for you.
So what do you say, go grab your trusty
Lincoln Electric AC-225 stick welder and let’s get started!
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 The first step is to drill bolt holes into the channel pieces that will
serve as the brackets. After securing the channel piece in a vice, drill a hole
at each end of the bracket. This will allow the bolts to slide easily through
and into the casing of the storage box. Handy Tip: Depending on how thick the
channel pieces are, you may want to keep both hands on the drill and apply steady
pressure to drill the holes.
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With that one simple step complete, let’s move on to the outside pieces,
fabrication, and safety equipment needed to complete the project. Note: We are using
a boat trailer in this example. You may have a different style trailer, so make adjustments
accordingly. The storage box will be secured between the upright post (which serves as a
mast support on the trailer) and the first cross bar. Four channel pieces will serve as
brackets and will have to be welded to the main “tongue” – one at each end and two in the middle. |
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Before we make the first weld, there are a couple of things to know. Since the first
bracket can only go as far as the first crossbar, this bracket needs to be welded first.
Be sure that the holes drilled in Step 1 are on the topside of the bracket. All other measurements
will be based on this single piece. The “C” shape formed by the channels will face inward and the
bin will rest on top. Ready to weld, think safety first – put on your welding gloves, safety goggles
and helmet. Make sure the channel piece is centered and even on the tongue. Place a stick of Lincoln
7018 AC into the electrode holder, attach the ground clamp to the trailer and make a small tack weld on
each side. An amperage setting of 120 is appropriate for the 7018 electrode being used.
A 1/8" diameter electrode is appropriate for this metal thickness. |
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Measure everything to be sure it is square. The spacing of the brackets depends
on the length of the box. So measure the box first. Handy tip: The good thing about tack welds
is that they can be easily removed with a quick knock of a hammer if you find that your measurements are off. |
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Now it’s time to tack weld the bracket on the opposite end, close to the upright.
Use the length of the box to measure the distance between the bracket you just welded and
the bracket you are now going to weld. Center the bracket on the tongue and measure the diagonal
lines from bracket-to-bracket to ensure they are square. |
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Using the same amperage settings for the electrode, put on all your safety equipment
(as mentioned in Step 3) and tack weld the second channel piece to the main tongue of the
trailer. This is a simple step, placing a small weld on each side of the channel piece.
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Time to weld the two center brackets to the main tongue. Handy Tip: If you have a problem
striking an arc with the stick, check to see if there is paint or rust where you want to weld.
If there is, use a metal file to clear the metal down to its original base. You can paint over the welds later..
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Center the two middle brackets and make sure they are evenly spaced from the end channel pieces.
The box we are using has a corrugated bottom. If you are using the same style box,
measure the pieces to
ensure they match up with the corrugation so the bolts are long enough to fall through both the box and
the channel bracket. Now tack weld each of the channel pieces. When done with the tack welds and you are
sure all is square, weld along all the joints in order to entirely fuse the channel pieces to the tongue. |
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Once the welding is complete, place the storage box on top of the channel brackets.
Locate all the holes you drilled into the brackets earlier and using chalk, mark these holes on the box.
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Remove the box from its mounting place and turn it upside down onto a flat surface.
With the holes clearly marked, begin drilling holes into the box on each chalk spot. |
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Drum roll please! The final step. Place the box back on the brackets, line up the holes and drop
a bolt with a flat washer through each hole. Secure all the bolts with another flat washer and a lock
washer and nut from the inside. |
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Presto! Your trailer storage box is complete and ready to cart around all your stuff!
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Fabrication Tools
- Lincoln Electric AC-225 welder
- 1/8" Lincoln 7018
AC Electrode
- Storage bin (You can use anything you can get your hands on and be a
little creative on exactly how you attach it.)
- Standard drill
- Metal file
- 3/8” bolts and nuts
- Flat washers and lock washers
- 4 pieces of 3” channel cut to size (these would be the mounting brackets
for the box – since they are pretty thick, you may want
to get them cut somewhere, or you can give it a go yourself with a
reciprocating saw.)
- C-clamps
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Safety Equipment:
- Long sleeve cotton shirt – don’t wear polyester!
- Safety glasses
- Welding helmet or face shield
- Welding gloves
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To learn more about the AC-225 welder
click here!.
Or, read up on all you need to know about Lincoln 7018 AC and other stick electrodes by
clicking here.
Related
Articles
How to Strike and Establish an Arc
Creating High Quality Stick Welds: A User's Guide
Arc Welding Fundamentals
Stick Weldirectory
This
project has been published to show how individuals used their ingenuity
for their own needs, convenience and enjoyment. Only limited details are
available and the projects have NOT been engineered by the Lincoln Electric
Company. Therefore, when you use the ideas for projects of your own, you
must develop your own details and plans and the safety and performance
of your work is your responsibility.
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