This is the axle donor.  Apparently, everything after '97 is coil-sprung/IRS.
Hits: 644
Size: 57.71 KB
Posted: 10/6/11
This is the axle donor. Apparently, everything after '97 is coil-sprung/IRS.
This one had the same axle, but others of the same year range have a smaller lug pattern, so pay clo...
Hits: 493
Size: 51.55 KB
Posted: 10/6/11
This one had the same axle, but others of the same year range have a smaller lug pattern, so pay clo...
I chose this donor because the brackets are designed to mount to a nearly-flat surface.  Only the re...
Hits: 616
Size: 85.74 KB
Posted: 10/6/11
I chose this donor because the brackets are designed to mount to a nearly-flat surface. Only the re...
This cost less than $100, which is less than a cheap trailer axle alone.  This one includes brakes, ...
Hits: 676
Size: 94.08 KB
Posted: 10/6/11
This cost less than $100, which is less than a cheap trailer axle alone. This one includes brakes, ...
Just measurements taken during the planning stage.
Hits: 487
Size: 84.32 KB
Posted: 10/6/11
Just measurements taken during the planning stage.
Just measurements taken during the planning stage.
Hits: 530
Size: 77.66 KB
Posted: 10/6/11
Just measurements taken during the planning stage.
I chose this axle for its deep drop.  The lack of ground clearance doesn't matter since the cross tu...
Hits: 460
Size: 96.44 KB
Posted: 10/6/11
I chose this axle for its deep drop. The lack of ground clearance doesn't matter since the cross tu...
The shocks hang slightly lower than the drums, which is perfect - they're expendable, so they'll pro...
Hits: 583
Size: 73.65 KB
Posted: 10/6/11
The shocks hang slightly lower than the drums, which is perfect - they're expendable, so they'll pro...
This axle has the common 5-on-4.5" lug circle, but the larger 2.8" hub stickout, so rims s...
Hits: 476
Size: 85.75 KB
Posted: 10/6/11
This axle has the common 5-on-4.5" lug circle, but the larger 2.8" hub stickout, so rims s...
Just measurements taken during the planning stage.
Hits: 481
Size: 82.7 KB
Posted: 10/6/11
Just measurements taken during the planning stage.
Just measurements taken during the planning stage.
Hits: 559
Size: 88.73 KB
Posted: 10/6/11
Just measurements taken during the planning stage.
While checking the fit without the brackets, I found the front bolts seized in their bushings.  This...
Hits: 1438
Size: 135.64 KB
Posted: 10/6/11
While checking the fit without the brackets, I found the front bolts seized in their bushings. This...
While checking the fit without the brackets, I found the front bolts seized in the bushings.  This b...
Hits: 1143
Size: 118.2 KB
Posted: 10/6/11
While checking the fit without the brackets, I found the front bolts seized in the bushings. This b...
Small wonder they were seized - I doubt any amount of hammering would have removed them.  Certainly ...
Hits: 1062
Size: 101.62 KB
Posted: 10/6/11
Small wonder they were seized - I doubt any amount of hammering would have removed them. Certainly ...
Just checking - nothing is drilled or bolted yet.
Hits: 597
Size: 87.97 KB
Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.
Just checking - nothing is drilled or bolted yet.
Hits: 550
Size: 71.64 KB
Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.
Just checking - nothing is drilled or bolted yet.
Hits: 566
Size: 82.28 KB
Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.
Just checking - nothing is drilled or bolted yet.
Hits: 567
Size: 77.16 KB
Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.
Just checking - nothing is drilled or bolted yet.
Hits: 534
Size: 65.38 KB
Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.
Eventually, I settled on this orientation: the front brackets bolted to the web of the I-beam, and t...
Hits: 544
Size: 99.94 KB
Posted: 10/6/11
Eventually, I settled on this orientation: the front brackets bolted to the web of the I-beam, and t...
I'll probably reinforce the holes thru the flanges, but this is good enough to get it rolling.
Hits: 539
Size: 97.12 KB
Posted: 10/6/11
I'll probably reinforce the holes thru the flanges, but this is good enough to get it rolling.
The gap is almost exactly 3/4", so I'll use plywood for the deck.
Hits: 526
Size: 71.85 KB
Posted: 10/6/11
The gap is almost exactly 3/4", so I'll use plywood for the deck.
To prep it for welding, the frame is strapped together.
Hits: 592
Size: 100.1 KB
Posted: 10/6/11
To prep it for welding, the frame is strapped together.
A carbide-tipped rip blade works surprisingly well on Aluminum.  Even thick stuff.
Hits: 504
Size: 93.33 KB
Posted: 10/6/11
A carbide-tipped rip blade works surprisingly well on Aluminum. Even thick stuff.
The floor joists are a snug fit.
Hits: 563
Size: 110.32 KB
Posted: 10/6/11
The floor joists are a snug fit.
I've tacked the tongue together, and it's pinned to the leaf spring brackets so the deck can tilt.
Hits: 547
Size: 97.43 KB
Posted: 10/12/11
I've tacked the tongue together, and it's pinned to the leaf spring brackets so the deck can tilt.
The tongue is long enough that the frame clears a fullsize truck bumper, and the jack is back enough...
Hits: 537
Size: 95.58 KB
Posted: 10/12/11
The tongue is long enough that the frame clears a fullsize truck bumper, and the jack is back enough...
The single L e-brake cable has been swapped for a 2-piece R so they match.  I'll cut the tubular gui...
Hits: 528
Size: 95.12 KB
Posted: 10/13/11
The single L e-brake cable has been swapped for a 2-piece R so they match. I'll cut the tubular gui...
27.5" should be just enough room between the front 2 floor joists for a hidden spare tire.
Hits: 509
Size: 100.71 KB
Posted: 10/13/11
27.5" should be just enough room between the front 2 floor joists for a hidden spare tire.
I borrowed a Lincoln wire-feed and burned the tongue together.  It's certainly not professional-qual...
Hits: 486
Size: 100.2 KB
Posted: 10/25/11
I borrowed a Lincoln wire-feed and burned the tongue together. It's certainly not professional-qual...
I finally came up with an idea for the the e-brake cable brackets that eliminates one set of tubes, ...
Hits: 449
Size: 82.35 KB
Posted: 10/26/11
I finally came up with an idea for the the e-brake cable brackets that eliminates one set of tubes, ...
The cable easily clears the tire, and will have even more room after I add the 2" wheel spacers.
Hits: 468
Size: 89.48 KB
Posted: 10/26/11
The cable easily clears the tire, and will have even more room after I add the 2" wheel spacers.
There's a tab behind the spring backet that prevents it from rotating on the single bolt.
Hits: 500
Size: 83.78 KB
Posted: 10/26/11
There's a tab behind the spring backet that prevents it from rotating on the single bolt.
The tongue tilts on the front spring brackets.  The center of the deck is very slightly forward of t...
Hits: 478
Size: 99.62 KB
Posted: 10/26/11
The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t...
The tongue tilts on the front spring brackets.  The center of the deck is very slightly forward of t...
Hits: 477
Size: 99.36 KB
Posted: 10/26/11
The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t...
The tongue tilts on the front spring brackets.  The center of the deck is very slightly forward of t...
Hits: 473
Size: 95.16 KB
Posted: 10/26/11
The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t...
This is the first time I've actually fitted everything at once.  The shock mounts will have to move ...
Hits: 550
Size: 63.47 KB
Posted: 10/31/11
This is the first time I've actually fitted everything at once. The shock mounts will have to move ...
The slot on the other side was too high - the bolt hit the frame.  So I swapped the tubes & cut the ...
Hits: 479
Size: 70.69 KB
Posted: 10/31/11
The slot on the other side was too high - the bolt hit the frame. So I swapped the tubes & cut the ...
The ammo can will hold straps, spare lug nuts, tire chocks (etc.), and the lug wrench stows neatly b...
Hits: 461
Size: 94.9 KB
Posted: 10/31/11
The ammo can will hold straps, spare lug nuts, tire chocks (etc.), and the lug wrench stows neatly b...
2-inch spacers are just what it needed to clear the frame.
Hits: 480
Size: 102.85 KB
Posted: 11/3/11
2-inch spacers are just what it needed to clear the frame.
These spacers came from eBay.  They're not listed for a '97 Caravan because the lug threads are diff...
Hits: 489
Size: 98.39 KB
Posted: 11/3/11
These spacers came from eBay. They're not listed for a '97 Caravan because the lug threads are diff...
I finally found some junkyard lift struts that would fit & work to hold the deck tilted, and install...
Hits: 466
Size: 110.84 KB
Posted: 11/11/12
I finally found some junkyard lift struts that would fit & work to hold the deck tilted, and install...
I finally found some junkyard lift struts that would fit & work, and installed them. To keep them fr...
Hits: 464
Size: 112.02 KB
Posted: 11/11/12
I finally found some junkyard lift struts that would fit & work, and installed them. To keep them fr...
I finally found some junkyard lift struts that would fit & work to hold the deck tilted, and install...
Hits: 426
Size: 106.07 KB
Posted: 11/11/12
I finally found some junkyard lift struts that would fit & work to hold the deck tilted, and install...
To keep the pin from ever going missing, I cabled it to the trailer.
Hits: 361
Size: 78.34 KB
Posted: 6/15/13
To keep the pin from ever going missing, I cabled it to the trailer.
Cables on the front of the spare tray will keep it from sagging, or the spare from sliding too far f...
Hits: 377
Size: 92.69 KB
Posted: 6/15/13
Cables on the front of the spare tray will keep it from sagging, or the spare from sliding too far f...
These little covers should be enough to keep me legal, and they're just strong enough for me to sit ...
Hits: 393
Size: 87.58 KB
Posted: 6/15/13
These little covers should be enough to keep me legal, and they're just strong enough for me to sit ...
These little wheel covers should be enough to keep me legal, and they're just strong enough for me t...
Hits: 409
Size: 95 KB
Posted: 6/15/13
These little wheel covers should be enough to keep me legal, and they're just strong enough for me t...
The stake pockets are spaced the same, so these rails fit in any position.

The fiberglass reflectiv...
Hits: 522
Size: 108.44 KB
Posted: 8/1/13
The stake pockets are spaced the same, so these rails fit in any position. The fiberglass reflectiv...
 

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