Windsurfer Trailer

Another windsurfer trailer The trailer chassis is constructed of galvanised steel, weighs around 120 kg and is rated to 600 kg. It’s designed to carry a catamaran or sailing dingy so its built relatively light considering it’s length of 4.6m. It seems trailers of these dimensions are usually designed to carry heavier loads and they were overkill for carrying around 100 kg. So I rang a local catamaran manufacturer to see who makes “light” weight trailers and he said he did it as a side line. He did a great job at around half the cost of quotes from trailer manufacturers. I have some basic woodworking skills so decided to make a plywood box with pine framing inside. The construction consisted of making 1200 mm × 600 mm frames, five of them. The trailer chassis has 4 cross members so after laying down the bottom ply sheet the frames are bolted to the chassis, the other sides of the box were then screwed on. I used 30 × 45 mm sections as corner fillets to ensure a join between the ply panels. The box ended up weighing 75 kg, a bit more than I’d hoped for. Access to the box is via the locked back door which folds down. Inside I padded the frames with foam. There are no racks and since everything packs fairly snug I don’t strap anything down. Originally the box had a flat square nose. I’ve since added a curved nose made of fibreglass which adds a bit more space at the front and possibly reduces drag. This curved nose opens like a bonnet on a car. The following fits in without too much trouble: 3 boards (155, 95 and 75 litre), 6 sails, 2 masts and 2 booms (around 80 kg). It also has roof rack to carry a long one piece mast and sometimes a longboard. So all up I estimate the weight of trailer+box+equipment = 280 kg. Approximate cost in Australian dollars. • Trailer chassis road registered (13in alloy wheels) $900 • Plywood 2400 mm × 1200 mm × 6.25 mm (×4) C/D quality ie. cheapest $140 • Pine 75mm × 45mm × 22 m and Pine 45mm × 35mm × 12 m $160 • Bolt deadlock, hinges, screws, bolts, paint etc. • Nose extension (fibreglass, veneer etc.)

1

2

800mm

4600mm

Trailer weight = 120 kg (tare) Galvanised steel 13” alloy wheels Rated to 800 kg

1111 0000 0000 1111 0000 1111 0000 1111 800mm

800mm

1111 0000 0000 1111 0000 1111 0000 1111

1400mm

Figure 1: Trailer chassis 3

45 x 35 mm

75 x 45 mm

600 mm

2800 mm

Framing joint 1200 mm

Figure 2: The box

4

600 mm

1200 mm

5

3300 mm

Figure 3: Side and top views of the box.

Top View

Side View

2800 mm

500 mm