Personalizing a new, inexpensive bumper pull car hauler trailer

[Brucker]

We recently were asked to make some modifications to a clients brand new trailer. The trailer in question is a basic, inexpensive, 7000 pound capacity, bumper pull car hauler. Shown here:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51012&d=1604189186

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51011&d=1604189186

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51014&d=1604189186

The desired modifications include adding a little structure in order to make it a tad more sturdy, a standard 2" receiver hitch, good amount of lockable storage, and a receiver mounted winch with both wired and wireless controls. These modifications along with the client's drop in anchor points and Mac brand straps, should make for a decent towing platform for years to come.

To start, we will need to add a little structure to the tongue of the trailer. Here is what we started with:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51015&d=1604189186

Cut a piece of angle iron to serve as a lower cross member to tie the frame sides together while tying into the deck structure as well. It is notched to fit inside of the frame rails and to allow the wiring to still pass along the driver side frame rail.

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51017&d=1604189347

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51016&d=1604189347

And tack welded it into position:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51018&d=1604189347

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[Brucker]

The front top rail was then cut to accept a standard 2" receiver hitch:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51022&d=1604189498

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51023&d=1604189498

And a piece of tubing was cut to fit between the new cross member and the bottom of the hitch. A 1/4" plate was welded inside of the tubing, along the top and bottom as well as plug welded in a few spots, to provide some extra support as well as so it could be drilled and tapped at a later time for the future storage box mounting.

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51024&d=1604189498

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Then welded the pieces into position:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51027&d=1604189648

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https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51039&d=1604190076

[Brucker]

Next up is adding some gussets to the sides of the top rail, as well as welding out the tops of the angle iron that attaches to the top rail. This wasn't done from the factory.

Gussets:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51031&d=1604189811

Sides of the top rail prepped:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51033&d=1604189811

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Welding gussets into place:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51043&d=1604190232

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Welded the tops of the angle to the top rail:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51053&d=1604190508

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51057&d=1604190627

Completed gusseted and welded top rail:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51052&d=1604190508

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https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51059&d=1604190627

[Brucker]

Mounting for the aluminum lockable storage box welded into position and drilled and tapped:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51047&d=1604190337

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51046&d=1604190337

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51080&d=1604196761

Mounted the aluminum box to the front of the trailer using some mounting plates and bolting it to the trailer:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51075&d=1604196645

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51105&d=1604198721

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https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51054&d=1604190508

[Brucker]

Our client want to be able to store the multi-mount winch within the lockable box. It will easily fit, but could slide around within the box. That much weight constantly shifting, and banging into the thinner aluminum walls, will eventually damage the box without reinforcement. So it will get some to the lower 1/3 of the box.

We start by cutting some small c channel and using our custom shop built punch press to put some speed holes through it.

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51061&d=1604196315

And started assembling the pieces together by welding:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51066&d=1604196422

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And installed the assembly onto the trailer:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51067&d=1604196422

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[Brucker]

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51076&d=1604196761

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Painted:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51087&d=1604197011

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Painted with box installed:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51099&d=1604197244

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51104&d=1604198721

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[Brucker]

With the structural work completed, we start on the multi-mount winch setup. The client opted for a NOS Smittybilt XRC8 winch after seeing our setup that has been abused for the past 7 years and yet id working well still. They also opted for an off the shelf multi-mount. And an inexpensive wireless remote setup for it as well. and a nice wiring quick connect setup for the truck.

The NOS winch:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51114&d=1604199087

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51115&d=1604199087

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Wiring:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51107&d=1604198864

Multi-mount:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51101&d=1604198721

[Brucker]

Assembling:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51112&d=1604199087

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51113&d=1604199087

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New setup verses our 7 year old setup:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51120&d=1604199184

[Brucker]

Mounted to the trailer:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51122&d=1604199646

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51121&d=1604199646

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Stored away in the lockable aluminum box:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51128&d=1604199744

Finished product:

https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51131&d=1604199917

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https://www.frontrange4x4.com/forums/attachment.php?attachmentid=51133&d=1604199917

[FINOCJ]

And I am just trying to figure out how to fabricate a hi-lift mount for my rear bumper....looks nice....is there anything in the box to keep the winch from sliding around....I know you reinforced the box, but still, I don't think I'd want that thing sliding and banging and bouncing around.

[Brucker]

looks nice....is there anything in the box to keep the winch from sliding around?

Thank you for the kind words.

No, there is nothing other than the exterior reinforcement. The client did not want anything else. Honestly I had to "talk" him into any reinforcement. As he put it, the box is for holding straps, tie down anchors, and spares. The winch will ride in the hitch, and only be stored in the box.

[newracer]

I like the gussets on the rail, my trailer could benefit from that.