Project Description
When Liz and I took our Escalante trip in the summer of 2005, we quickly realized that in ordered for us to sleep under the stars we would need to find an alternative for all of our gear storage. Loading totes in and out of the bed of the truck was not going to cut it so we started looking for an alternative - small trailer. Military jeep trailers are good choices because they are tough, yet reasonably lightweight. After a little looking around and sending a few e-mails, I located an m416 jeep trailer just north of Phoenix by about 45 minutes. it was straight, reasonably rust-free, and had the original pintle-style hitch system that is another benefit of these old jeep trailers. This is my collection of the tear-down and complete rebuild of this 1966 M416 Jeep Trailer. I hope you find the notes and pictures useful when tackling your own Jeep trailer project. If you have questions, feel free to contact me using this form. I'm more that happy to help out with a measurement or clarification. |
Design Features
- Axle flip – The axle flip will entail a complete rebuild of the axle and relocation to the underside of the leaf springs.
- Cut and weld tailgate ( side swing) – the m416 trailer was originally designed to float over 500lbs.therefore, there was no tailgate. After much thought, I decided to cut a tailgate and mount the hinges so it swings out to the left side of the trailer. This will allow a small kitchen box to be hung off the side of the tailgate and the bed surface to be used as general work area. I may look into acquiring the mounting hardware From an old land cruiser or jeep tailgate to simplify the fabrication. I also need to obtain a mechanism to lock the tailgate in its open position to prevent swinging.
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Tongue box – The primary purpose of this box is to hold all of the electrical equipment. This will include the trickle charger, deep cycle battery, power inverter, switch box, and what other electrical devices wind up on the trailer. Actual: This didn't quite end up the way I had planned at first. After several hours of design consideration, I decided that I wanted a cooler rack on the tongue and the electrical elsewhere. |
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Neal from Glendale Powder Coating smoothes out the new opening for the tailgate.
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| Lid system ( hinged with rack components) – the lead system will be designed of steel or aluminum and in such a way to form a watertight seal on the bed of the trailer. This lightweight get strong lid system will be hinged at the front and lifted by two large lift struts. The outer surface can be made from aluminum or steal, but the internal structure should be designed to hold several hundred pounds of gear on top without collapsing. There should also be some sort of basic locking mechanism to prevent unauthorized access. On top of the lid system will be mounted a factory roof rack of a Ford expedition or like vehicle. On top of that will be mounted a 2ft. by 6ft. safari basket and two bicycle rails such as those made by the Yakima. This will allow for additional gear storage in a simple method for accessing the bikes. A factory roof rack system will be used to ensure the availability of parts from common rack manufacturers and the addition of other carrying devices such as those for kayaks, surfboards etc. | |
| Rewire – The original trailer wiring is setup for a 24 volt blackout lighting system that runs on a 12 pin connector. Needless to say that won’t look up to my Ford. My goal is to wire it for normal trailer lighting operation and to draw enough power off the trailer break lead to perform a trickle charging function on the deep cycle battery. I also plan on installing a power inverter to allow for small 120 volt operation. If I get real ambitious, I may try designing some LED lanterns for the kitchen area. | |
| Fresh water tank – this one’s pretty simple. I would like to install a 25 to 35 gallon freshwater tank under the trailer and plumb it for easy access | |
| Canopy extension – Since the kitchen area will be off the back of the trailer, I would like a canopy to be designed to unroll from the underside of the lid system when elevated. Ideally, tent-like polls could be sprung from the corners of the canvas sail to mounting pockets in the bed. This one still needs to be tested and may require more cross bracing or ground polls. |
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| Kitchen box ( to hang off tailgate) – when I go camping there’s nothing I like more than an organized kitchen that I can get in and out of quickly. The kitchen box would be a fold down aluminum box that would hang off the tailgate when opened and store the stove, cook pots, eating utensils, etc. – pretty much everything but food. |
Parts List
| Part/Service | Estimate | Actual | |||
| General | |||||
1966 M416 Trailer Purchased from a gentleman in New River Arizona. He bought it to do what I'm doing, but never got around to it. His loss, my gain. |
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800 | 750 | ||
1/4 ton Jeep Trailer Safety chains (pair, plus shipping) Actual: Used coiled cables due to noise issues off road. No sense listening to chains clank for hundreds of miles and besides, I'm not dragging much weight. |
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25.00 | 13.80 |
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| AZ title transfer | 100.00 | ||||
Hardware Well, I finally stopped by Copper state and picked up all the hardware. Stainless for the exposed pieces and grade 8 plated for the structural. Still need to pick up some of the spacers, pins, etc. Picked up the extra hardware. 13.02 - Man is steel getting pricey. |
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75.00 | 90.58 | ||
2 16x8 wheels with 5 on 5.5 bolt pattern Actual: I ended up scoring a set of wheels to match my truck. 16 x 7 with a 5 x 135 pattern. Need to adapt them using the adapters below. Got a screaming deal on a set of 4 off of eBay. |
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150.00 | 107.50 | ||
2 Wheel Adapters I didn't want to do it this way, but it turned out to be the only option that made since. I thought I had a machine shop that would mill out the hub bore, re-drill the pattern to 5 x 5.5 and install hardened seats, but then I would be stuck with two spares again. I decided that 1 inch spacers would have to do. I got mine from http://www.performancewheel.com. Their staff seems pretty knowledgeable and helpful and the guy I spoke with threw in the lug nuts. Got the spacers in and needed to shorten the lugs on the trailer. A few minutes with the sawzall and I was back in business. Now the fenders are too narrow for the tires so I will be looking into having a custom fender made. |
100.00 | 128.00 | |||
2 Mud Terrains 265 75r 16, mounted and balanced Actual: I decided to use wheel adapters to leave the stock axle, but match the truck's bolt pattern. This way I can replace the truck tires a bit early and move the old ones to the trailer. Plus, I only need to carry one spare. As it turned out, I changed the tire sizes on the truck, so ended up buying new tires for the trailer. Since I had a tire credit from a road hazard warranty, two new yokohama geolander AT-2 cost $132.00 Not bad, and I can rotate all six tires. |
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300.00 | 132.00 | ||
4 red reflectors (replacements) Actual: Only two were actually so I picked up a set at Checker Auto Parts. |
15.00 | ||||
2 Drain Plugs (Frontline Military) Actual: After scraping the dirt off it turns out that I didn't need a new set after all. Oh well, I already bought them. |
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30.00 | 27.00 | ||
| Chassis/Suspension | |||||
Wheel Bearings /Seals (frontline military) Actual: Bearing from M151 kit number 2530-00-887-1341 Spindle Nut Kit Ebay: 4x4Dude |
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40.00 | 65.90 | ||
Service: Press out races old races and in new I opted to beat on the races with a drift and a mallet for a while, but the would not budge. Finally took them down to NAPA to have the work done. I hated to do that, but time is money too. |
0.00 | 20.48 | |||
Axle/frame ubolts, nuts and washers (6 total) (Dunbar Spring Company, Phoenix, AZ ) Actual: I took them my springs to be re-banded and saw that they custom bend u-bolts. Two birds with one stone - I like that. |
40.00 | 45.00 | |||
Shocks Actual: These are the boring Monroe Gas Magnum shocks. I found that if you flip the lower spring mounts, you can get by with a mid 70s cj5 shock. cool! I could have gone Rancho, but I didn't want to wait to order the right size. |
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60.00 | |||
Spring Eye Bushings (1950's CJ3A/B Front leaf bushings Energy Suspension 2.2101) |
15.00 | kept old |
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Spring "c" Shackles both Left and Right Hand Thread (eBay) Actual: New shackles are cheap. I couldn't bring myself to just do the bushings. The shackles I used are off a CJ2A chassis. |
0 | 28.23 | |||
Axle Bump Stops
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15.00 | 0 |
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| new urethane shock bushings ( Energy Suspension, part number 9.8108R) | 25.00 | w/shocks | |||
Receiver Tube 18" (for accessories, not towing) fits right through the back frame rail. |
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30.00 | 26.98 | ||
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| Electrical | |||||
Tail Lights
Actual: I wanted an industrial looking light and I think I got that with these GMC truck lights. Now I just need to figure out the wiring. |
60.00 | 45.00 | |||
| Wiring Harness (bulk wire, looms, adapter) | 40.00 | ||||
Storage tubes (ammo boxes) I couldn't pass these up. They are military surplus 155mm ammo tubes and have a quick lock twist seal that presses the metal end with "o" ring to make a waterproof seal. The steel tube is 26in long and 6.5 in diameter with two wider rings approx 8in on each end. I will have them powdercoated to match the trailer and outfit one with the battery, charger, inverter, etc. The other one will just be for storage of misc. items. Not sure what yet or where they will be mounted.
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0 | 32.60 | ||
| Body & Accessories | |||||
| truck Boxes (dust tight containers) | 150.00 | ||||
Tail Gate The tailgate turned out to be more complicated that we first thought it would be. Once you cut the hole in the rear of the tub, the sides get really flimsy. Actually it's the floor that folds up if you push too hard on the sides. Neil decided that a steel frame was in order to make sure it's stout. Check out the gallery above for more details on the design. |
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trade | |||
Cover (Lid System Hardware) I ended up buying a latch system for a toolbox to secure the lid. Also included in this total are the handles for the tailgate and the pins for the hinges. All of it is stainless so that's why it added up to so much. |
trade | 95.46 | |||
| Sandblasting/Paint | trade | ||||
| Bed Liner | 150.00 | ||||
Lift struts (cover) shocks Bought 2 250 lbs gas struts from www.mcmaster.com This shop has an awesome catalog and I think the shocks will be perfect under load. We mounted them at the front of the bed to weaken them a bit. One is perfect unloaded, so a second one with gear in the basket and bikes on the rack should do the trick. |
60.00 | 67.24 | |||
Roof rack (Yakima 58 in Perm. Mount with bike carriers) Actual: Bought a set of Rail Rider towers on Ebay for $20.50 and will have 5 - 10 dollars in replacement hardware. These will be mounted directly to tracks or even directly to the top itself. I bought two Yakima Raptor bike mounts on eBay for $43.00. These will go on either side of the gear basket. |
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80.00 | 64.50 so far | ||
| tongue box | trade | ||||
| Kitchen box | trade | ||||
| TOTAL | $2510.00 | $1405.87 |
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| Wish List | |||||
| ARB Cooler | 800.00 | ||||
| high lift jack | 70.00 | ||||
| Water Tank | 45.00 | ||||
Canopy/Tent |
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| Battery System (Orbital, inverter, wire, connectors) | 150.00 |
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| TOTAL | |||||






























