I've never liked the way my trailer frame stops short and the bunks hang way off the back. I know this is common, but it doesn't look right to me.
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I can't justify buying a new trailer, so I picked up a couple I-beam end cuts from a trailer manufacturer and some C-channel from a metal shop. I had a guy lined up to weld if for me, but he got too busy and I got impatient. I only have a gas welder and a stick welder and I had never welded aluminium before. After some internet searching I found a bit of information that you can stick weld aluminium. Just a bit though. 90% of the info out there was that you can't stick weld aluminium. Well....won't know for sure until I try. I picked up some rods and burnt 4 or 5 practicing, then went for it. Now I am not what you could call an experienced welder. I'm about as amateur as you can get. I weld something about once a year; if that. After what I had read, I was surprised at how good my welds were. It really wasn't that big of a deal. Yes, they looked like crap; but they did get better as I progressed and I was grinding them down anyways. I'm sure someone that welds regularly could get a good bead going in no time. Some may feel this is a waste of time because it has no structural integrity and is only cosmetic, but it bothered me. Overall, I'm happy with what I ended up with.
Trailer2.jpg
Trailer3.jpg
I then added center bunks to help guide boat and replaced the stock front V-guide and roller with a pair of V-blocks and put new carpet on everything. I also installed a new winch. Winch is a beast. 2spd 3200lb, pulled the boat up the bunks on flat ground with ease.
Bunks.jpg
Winch.jpg
I then cleaned up the frame using Scotchbrite pads. (An idea I got from George Carter that is quick, easy, and gets good results). I used my jitterbug sander with the Scotchbrite and it took me no time to get the rails looking new again.
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Final touch was to add the all important Donzi markings.
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