Building a Kart Trailer

By RS250, 15 June, 2010
Since everyone made fun of my unpainted trailer used for Phillip Island, I've decided to build a new one, simply because the Stock Honda wouldn't fit inside the old one. :-[

This new trailer started life off as a 7"x 5" box trailer, however you can use a 8"x 5" instead if you don't want the make the nose mod up the front.

You then make the slippiest and most practical trailer with 2 side doors and 1 rear door using a standard box trailer as the base to which to work from. The support bars across the top are the correct distance to support another kart tied to the outside roof of the trailer. I used 20x20x1.5 square tubing to make it light but strong. All additional steel weighs 35kgs however I lost about 17kgs from the box trailer's original rear door. I plan to cover it with 0.55mm thick colourbond sheeting.

Inside fits;
1x 250 twin
1x 3mx3m ezyup
2x large tool boxes
2x 20L fuel drums,
2x complete sets of wheels/tyres

Took me 4 days to build, will take 5 days when the sheeting and locks go on.
I was a bit of a novice welder with the stick, I'm pretty handy with it now. ;)

[img]http://www.samzavaglia.com/hosting/trailer/DSC01970.JPG[/img]
[img]http://www.samzavaglia.com/hosting/trailer/DSC01971.JPG[/img]
[img]http://www.samzavaglia.com/hosting/trailer/DSC01976.JPG[/img]
[img]http://www.samzavaglia.com/hosting/trailer/DSC01974.JPG[/img]
[img]http://www.samzavaglia.com/hosting/trailer/DSC01975.JPG[/img]

Comments44

Rolf Greve

14 years 8 months ago

Mate,
That would look fully sik with some fancy Aero and wheels.
Cookie has them fin things mate
;)

The Cook

14 years 8 months ago

[quote author=Rolf Greve link=topic=1016.msg8047#msg8047 date=1276583333]
Mate,
That would look fully sik with some fancy Aero and wheels.
Cookie has them fin things mate
;)
[/quote]

Mate. Stop picking on little Sammy. He's done a great job. What I want to know is, Where's the towball on the back of the #9 machine?

SuperkartAUS

14 years 8 months ago

I'm more worried about the oil leak under the trailer....have you checked the gearbox seals on that #9 thing lately?

Nice work though!

The Cook

14 years 8 months ago

[quote author=Mike Wayne link=topic=1016.msg8053#msg8053 date=1276619037]
I'm more worried about the oil leak under the trailer....have you checked the gearbox seals on that #9 thing lately?

Nice work though!
[/quote]

Nice work Mike. Could have been a disaster if that leak wasn't detected. You kept your head in all the excitement of Sams new trailer. ;D ;D

Rolf Greve

14 years 8 months ago

OH NO,
Still cutting half laps?
Where's the stamina?
No wonder IT is no more.

RS250

14 years 8 months ago

[quote author=Jason Laker link=topic=1016.msg8058#msg8058 date=1276734185]
Don't worry about Sammys trailer, last night at Eastwood Leagues Club his co driver was doing all the hard yards handling the half full beers again for SZR.
[/quote]
How else am I suppose to take advantage of the co-driver?
Didn't you know that beer is what makes ugly people have sex?

Rolf Greve

14 years 8 months ago

[quote]How else am I suppose to take advantage of the co-driver?
Didn't you know that beer is what makes ugly people have sex?[/quote]

[size=10pt][[color=navy]Jeez[/color][/size] mate don't let that one get back.

RS250

14 years 8 months ago

On Friday I went to pickup the trailer sheeting (0.55mm thick colorbond) for the trailer from Stratco. I asked them if they had any waterproof/sealed pop rivets. They look at me like I was the work experience kid that got sent for a left hand screwdriver or something. Anyway after the 5 experts got together, they worked out that it does not exsist, infact their words were "You can get a bag of them next to the striped paint". Anyway, so I got the pre-cut sheeting off them and that was it.

This morning I'm in Bunnings, in the rivet section and found........."Sealed" rivets. 3/16 pack of 100 for about $11.00.

I might go to Stratco and pop rivet all their arse cheeks together with the sealed rivets so they don't leak shit again. ;D

[img]http://www.samzavaglia.com/hosting/trailer/sealed%20rivet.jpg[/img]

PIL007

14 years 8 months ago

If you want the sheets to remain sealed for a shit load of years, use marine Sikaflex. Preferably black but it's sticky messy stuff be warned.
BTW I wasn't aware that Trace drank such large quantities of lager. Next 6 pack is for her.

RS250

14 years 8 months ago

Done my last bit of welding last night with an inside roof rack to carry my foldaway table. The 4 door locks are on.
I have now spraypainted the top frame with gunmetal grey hammer finish paint using my compressor and spraygun. I thinned out the paint 20% with turps and it's now a perfect flat finish gunmetal grey, looks a million bucks. I'm impressed even if I say so myself.

I already got 2 tubes of Sikaflex 227 from Supercheap which is only $18.00 a tube to stick the panels onto the frame and stop all the vibration and sound deadening, plus water proof all the seams from the trailer manufactuer. This stuff can be later sanded and painted over as well......it's good shit. Then I pop rivet the panels as well.
[img]http://media.supercheapauto.com.au/sca/images/11079.jpg[/img]
Gotta say, this is a much bigger job than I originally thought if you want to do the whole thing properly.......

Rolf Greve

14 years 8 months ago

Sam,
I have used the sikaflex on the old boat a bit too. Its great.
You can clean spillybits with a very wet rag, like silicone.
Good luck

RS250

14 years 8 months ago

Painting of the frame completed.
[img]http://www.samzavaglia.com/hosting/trailer/DSC01978.JPG[/img]
[img]http://www.samzavaglia.com/hosting/trailer/DSC01979.JPG[/img]

Hope to Sikaflex all the seams and stick the panels on this weekend.
After all the panels are stuck on and pop riveted, then a final paint job of the entire outside.

The Cook

14 years 7 months ago

Drill the rivet holes before you sikaflex the sheeting Sammy. That way you get rid of all the drill swarf and it is not stuck between the sheet and frame.

RS250

14 years 7 months ago

I decided the make the trailer pigeon proof from landing and dropping shit, also doubles as Cookie proof so he doesn't lean up against it and talk shit in the paddock....... not until he leans out his main jet at least 5 sizes in the Taylor-Wankel anyway. :D
[img]http://www.samzavaglia.com/hosting/trailer/DSC01981.JPG[/img]

RS250

14 years 7 months ago

The sheets are all Sikaflexed and pop riveted thanks to Stocky leading me his air-powered pop rivet gun. Just over 200 pop rivets in place. Thanks to the SikaFlex, there is no "tin rattle" when tapping or closing the doors. Sounds nice and solid. ;)

[img]http://www.samzavaglia.com/hosting/trailer/DSC01983.JPG[/img]

Sikaflex all the seams and welds inside and out to water proof the trailer.
[img]http://www.samzavaglia.com/hosting/trailer/DSC01984.JPG[/img]

Next is to paint the entire trailer outside of the trailer then attach the door locks and all the weather shields for the bottom of the doors and inside the doorjams.

PIL007

14 years 7 months ago

L.E.D's for tale lights would also be trick and mine has wheel arch lights that i though were a wank but they really help backing at night and getting in tight spaces. (especially your driveway)
Very nice job Sammy

The Cook

14 years 7 months ago

[quote author=PIL007 link=topic=1016.msg8171#msg8171 date=1277705751]
L.E.D's for tale lights would also be trick and mine has wheel arch lights that i though were a wank but they really help backing at night and getting in tight spaces. (especially your driveway)
Very nice job Sammy
[/quote]

Go the whole way Sammy. Under trailer flouro lights and a big arse subby would really set it off.

RS250

14 years 7 months ago

That's why I'm rushing to have it all fully sik so I can enter it for the 2010 Autobarn Sound Off.
http://www.youtube.com/watch?v=JJQCqhHwDp0&feature=related

RS250

14 years 7 months ago

According to this recent photo, the old trailer still looks like she needs a paint job.
Who's blue WRX? ;D ;D ;D
[img]http://www.samzavaglia.com/hosting/trailer/fast%20trailer.jpg[/img]

The Cook

14 years 7 months ago

Most likely the fastest the "old" trailer has ever gone. Makes it easier to paint after the cobwebs have been blown out of it and the rust bounced off.

RS250

14 years 7 months ago

Who get's busted doing a measly 71 kph. Could only be a member of Team Drongo Racing.
Fair Dinkium, I'm going to send the notice back to the Warwick Police Officer saying that your going to do much better than that on July 4 and again on August 15.

Rolf Greve

14 years 7 months ago

[quote]Who get's busted doing a measly 71 kph.[/quote]

Yeah..... In an 100 Zone...........

Someone slow....maybe.......

;)

RS250

14 years 7 months ago

With rolling starts, you can start racing as soon as you see the green flag ;D
Just so you know Drongo, that sign 25m up ahead, she still says [size=18pt]60[/size] mate, so you can forget about that "control line" on the race track. ;)

The Cook

14 years 7 months ago

I'm not on any side here but.

The sign ahead may be a 60 sign but being in QLD it is most likely in MPH.

Rolf Greve

14 years 7 months ago

Just heard Team TDR will be driving team TTR to the park in August.
Should see another photo after that little trip.

[i]Although the weight of the esky may slow the little blue machine a little.[/i]
:D

RS250

14 years 7 months ago

Team Drongo Racing will be driving Top Turd Racing to the track...... :D
That's in itself will be surely provide enough entertainment for a weekend.

RS250

14 years 7 months ago

Watch out, Dodgy Bros backyard spray painting.
[img]http://www.samzavaglia.com/hosting/trailer/DSC01986.JPG[/img]
[img]http://www.samzavaglia.com/hosting/trailer/DSC01988.JPG[/img]

Completed all the floor seams sealed with Sikaflex 227.
[img]http://www.samzavaglia.com/hosting/trailer/DSC01989.JPG[/img]

Simple latch to keep the back door open.
[img]http://www.samzavaglia.com/hosting/trailer/DSC01990.JPG[/img]

Touch of luxury, fitted with carpet incase anyone gets lucky on a race weekend. No responsability accepted for carpet burn.
[img]http://www.samzavaglia.com/hosting/trailer/DSC01992.JPG[/img]

refinisher

14 years 3 months ago

Jordan talk to the cookster he will be able to help you out at a very inexpensive rate

The Cook

14 years 3 months ago

Gavin.

I can't speak for Sam's particular trailer but I have seen a lot of the commercially available box trailers with welds across there, even though it is the biggest no-no. The ones I make are never welded on the top of the drawbar. Knowing the use Sam has with the trailer and the way he intends to balance the load he won't have any issues though.

RS250

14 years 3 months ago

I'm sure there are other welds holding that bar in place.
Take it up with Mario Trailers at Greenacre. They pump out at least 4 a day.
A better design would be to have a triangle support bars below it.
Anyway, all I did was pimp a standard box trailer into a carpeted shagging wagon. ;D

Oh yerr, it pissed down rain at Phillip Island on Friday night / Saturday, no water on the carpet. ;)

The Cook

14 years 3 months ago

[quote author=Sam Zavaglia link=topic=1016.msg9630#msg9630 date=1290331959]
Oh yerr, it pissed down rain at Phillip Island on Friday night / Saturday, no water on the carpet. ;)
[/quote]

Those sealed rivets, you know the one's not available, make all the difference Sammy. ;D ;D

RS250

14 years 2 months ago

I heard the Cookster has been busy welding electric winch kart stands, I've been busy welding a rack for my new kart transporter. I guess we can compare suntan's at Wakefield Pk.

Anyway Cookster, 1.5mm thick steel using the stick welder, didn't blow one hole. Your recommended 2mm thick is for pussies mate.

The new kart transporter comes complete with hair conditioning, power rack and pinion, fool injection and more comfortable seating position but has one major problem. For the same overall length as my previous sit on top of engine Hiace, I've lost 400mm in cargo length. >:(

Next thing to weld up will be the custom kart trolley that will fit in the van as racking/shelving while transporting but removes and doubles as kart trolley for which lines up to the back of the van for a one man job load/inload of the kart onto the rack.

[img]http://www.samzavaglia.com/hosting/trailer/IMG00110-20101123-1836.jpg[/img]
[img]http://www.samzavaglia.com/hosting/trailer/IMG00109-20101123-1835.jpg[/img]
[img]http://www.samzavaglia.com/hosting/trailer/IMG00108-20101123-1835.jpg[/img]
[img]http://www.samzavaglia.com/hosting/trailer/IMG00112-20101123-1931.jpg[/img]
[img]http://www.samzavaglia.com/hosting/trailer/IMG00103-20101123-1833.jpg[/img]
[img]http://www.samzavaglia.com/hosting/trailer/IMG00105-20101123-1833.jpg[/img]

refinisher

14 years 2 months ago

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