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  #1  
Old 08-11-2014, 01:15 PM
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bwilson bwilson is offline
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Join Date: Aug 2008
Boat: 2003 Mastercraft ProStar 209 350 MXC
Location: DFW
Posts: 42
Made a new trailer.

After I got back from the lake the last time I went out, I noticed the back of the trailer wasn't touching the boat anymore.


After further investigation I found both frame rails were rusted out and broken after the axle mount tubing.


I had already repaired a section of the middle cross member here so I knew rust was an issue already. (This repair was done under the boat with a MIG, hence the look)



The boat had spent some time in Florida where I am sure it was exposed to brackish water.


I called around to price a new trailer and got quotes anywhere from $4800 plus shipping to $8500. Lead time was considerable. I thought If I do it myself and reuse alot of the old gear I could save a ton of dough. The torsion axle seemed good, The disc brakes are still good (actuator was shot). Good wheels, just need some new tires. So I decided to dive it and set the boat aside.


To make sure I got all the dimensions the same I am going to build the new trailer on top of the old one, then cut the old trailer out from underneath it. I also made 4 templates out of OSB to replicate the stringer hanger locations and the cross member locations.


The most difficult part so far has been the main side rails. They are press bent 2x4 .120", I dont have access to a bender that will handle that so I need to pie cut the outside of the tubing and weld it back together.


I am a much better on the TIG than the MIG even though it takes longer, a prefer the process.





Borrowing Chunter's Prop guard method

Cutting tail light holes


I have a bunch of goodies on order. I'll post more pics soon. Trying to decide on paint color. Match the boat or gloss black?
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Last edited by bwilson; 08-11-2014 at 02:47 PM. Reason: fixed pics
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  #2  
Old 08-11-2014, 01:18 PM
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Dylan Dylan is offline
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Bravo! You might consider re-sizing the pictures, as they are huge.
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  #3  
Old 08-11-2014, 01:25 PM
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bwilson bwilson is offline
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Join Date: Aug 2008
Boat: 2003 Mastercraft ProStar 209 350 MXC
Location: DFW
Posts: 42
I know, I am trying to figure it out...pissed
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  #4  
Old 08-11-2014, 01:34 PM
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Sodar Sodar is offline
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Boat: '07 ProStar 197 w/ MCX
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Sweet project!

I like your way of getting the main frame rails bent. It should actually look pretty cool when it is all ground down and cleaned up. Unlike the frame rails that are bent on a tube bender, yours' won't have the crease on the inside of the bends. Cool stuff!
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1996 ProStar 190
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  #5  
Old 08-11-2014, 05:12 PM
snork snork is offline
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Look'n good
Impressive welds and attention to details
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  #6  
Old 08-11-2014, 06:13 PM
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1redTA 1redTA is online now
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impressive
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Old 08-11-2014, 06:17 PM
Olaff Olaff is offline
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Boat: 1982 Mastercraft Stars & Stripes Powerslot
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You GOTTA match the boat color!
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  #8  
Old 08-11-2014, 07:22 PM
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pmikler pmikler is offline
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heck of a job. I wish I had those skills.
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  #9  
Old 08-11-2014, 07:37 PM
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orbeamlb orbeamlb is offline
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Beautiful work. Can't wait to see the finished product!
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Old 08-11-2014, 07:56 PM
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CantRepeat CantRepeat is online now
 
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Boat: 06 X30
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Nice job on the jigs; they'll make setting up the bunks so much easier.

Two things I'd love to add to my shop: A bridgport and a lathe.
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