18BT53 5X3 Box Trailer Drawings PDF

ASSEMBLY GUIDE - 5x3 BOX TRAILER
750kg ATM UNBRAKED 5x3 BOX TRAILER

Rev 0 04/10/2016
INDEX
ITEM DRG No
ASSEMBLY GUIDE --
DRAWING PACK BT53
COMPLETE PARTS LIST --
MATERIAL CUT LIST --
IMAGES --
GENERAL INFORMATION: --
Weld Symbol Guide GPW 100
Electrical Diagram BT 007
Axle Selection GPA 360
Chassis Fixtures OT 020
Suspension Installation TB 025
RHS Steel End Caps GP 155
Coupling Mount Plates GP 020
Trailer Options Assembly TB 005
Panel Fixing ETS 020
Trailer Options Components TB 030
Spare Wheel Mount Plates GP 180
RHS Steel End Caps GP 155
Jerry Can Holder GPJ 500
© COPYRIGHT - TRAILERPLANS.COM.AU
ALSO FROM TRAILERPLANS…
4m Enclosed Motorbike Trailer 6m Enclosed Trailer 2.1m Enclosed Trailer

 SIZE: 4000 x 2000 x 1500mm  SIZE: 6000 x 2400 x 2000mm  SIZE: 2100 x 1200 x 1400mm
 ATM: 2600kg  ATM: 3500kg  ATM: 1750kg
 TARE: ±1000kg  TARE: ±1800kg  TARE: ±450kg
 LOAD: ±1600kg  LOAD: ±1700kg  LOAD: ±1300kg
 Up to 5 bikes, rear ramp, pop-up  Spacious, really spacious  Compact, secure, versatile
roof
Box Trailer Tandem Box Trailer Off Road Camper Trailer

 3 SIZES: 6x4, 7x4 & 7x5ft  3 SIZES: 8x5, 9x5 & 10x6ft  3 SIZES: 6x4, 7x4 & 7x5ft
 ATM: 750 to 2000kg  ATM: 2400kg  ATM: 1600kg
 LOAD: ±500 to 1750kg  LOAD: ±1600kg  LOAD: ±1000kg
 Versatile  Hard working, easy build  Because it’s better outdoors
Hydraulic Tipping Trailer Cage Trailer Motorbike Trailer

 SIZE: 3000 x 1800 x 600mm  SIZE: 3500 x 1710 x 1660mm  SIZE: 2200 x 1500mm
 ATM: 3400kg  ATM: 750 to 1500kg  ATM: 1000kg
 LOAD: ±2550kg  LOAD: ±400 to 1150kg  LOAD: ±750kg
 6-stage hydraulic cylinder  Rear drop ramp/tailgate  Light, economical, life changing
Luggage Trailer Single Axle Flatbed 2200 2500 Flatbed Trailer

 3 SIZES: 5x3, 6x4 & 7x4ft  SIZE: 4200 x 1950mm  SIZE: 4200 x 1870mm
 Hard sealed lid, under-body spare  Ramps & front stone guard  Winch bracket, tie-downs, ramps
Flatbed Tilt Trailer 3500 Flatbed Trailer Flat Top Wide Bed Trailer
 SIZE: 4200 x 1870mm  SIZE: 4800 x 1760  SIZE: 4800 x 2400mm
 Tilt assist (hyd/air), tie downs,  Heavy duty flatbed, real tough  Full width for wide loads
drop ramps and hard working
7m Boat Trailer Coming soon… Coming soon…

 SIZE: 7000 x 2300
 ATM: 3000kg
 TARE: ±1100kg
 LOAD: ±1900kg
 Spare wheel mount, winch post,
keel rollers
Weights & Measures
1500x900 (5x3ft)
ATM (maximum) 750 kg
GTM 660 kg
TARE ± 225 kg
LOAD CAPACITY ± 525 kg
BALL LOAD ± 90 kg
LOAD AREA 1500x900 (5x3ft)
OVERALL SIZE 2666x1400 (±9x5ft)
PREPARED BY
OKAJARO Pty Ltd
trading as TrailerPlans.com.au
ACN 147 897 961
Brisbane, Australia Tel: 0408 112 604
info@trailerplans.com.au
ANY QUESTIONS?
If you have any queries about these plans or during your build, please contact us through any of
the following means:
Website: www.TrailerPlans.com.au/contact
Email: info@trailerplans.com.au
Phone: +61 (0)408 112 604
IMPORTANT INFORMATION
We have taken care to ensure that these plans are accurate, of sound design and comply with
Australian Design Rules as summarized in the Vehicle Standards Bulletin 1, as provided. These
plans are offered as a guide to assist with the construction of the described trailer. It is ultimately
the manufacturer’s responsibility to ensure that the trailer is of sufficient build quality, complies
with national and local regulations, is legally registered for road use and maintained in serviceable
condition. We take no responsibility for losses that may occur as a result of trailers manufactured
using these plans.
Our plans a continually updated to include changes in legislation, design rules, industry updates
and corrections. If you have not obtained this set of plans directly from our website (or authorised
distributor) then it may not be the latest available release or an unauthorised copy and you are at
risk of following out-dated or incorrect advice and building a non-compliant or unsafe trailer.
Contents Description
Assembly Guide & Information
Complete and detailed assembly guide to help you through the construction process.
Trailer Drawings
Fully detailed parts and assembly drawings, dimensions, welding instructions and detailed
views. This is your main source of information during the construction phase.
Complete Part & Material Cut Lists
Use these to plan your build, draw up a shopping list, get quotes and draw up an accurate
budget. (Excel versions are available from the downloads page – see below)
Pictures
A few 3D Model images of what your trailer will look like if you build it to these plans.
Additional Drawings
 Electrical diagram, Panel Fixing
 Chassis Fixture & Weld Symbol drawings
 Axle selection & Suspension Installation drawings
 Optional component drawings & EXCEL files
Additional Downloads & Information

Follow the link below for further information specific to this plan. Our website also
contains a wealth of information that may be useful during the planning and
construction of your trailer.
 If you downloaded a PDF version of these plans, please obtain DXF & Additional
Files FREE from https://www.trailerplans.com.au/downloads/ and follow link to
LUGGAGE TRAILER – use password btfws8 when prompted.
 DXF Files are used by laser/profile cutting services to produce your flat sheet
parts. Each DXF file has an identical PDF document with the same file name.
 VSB 1 - The summarized authority of legislation and requirements for trailers
under 4.5 tonnes. The above drawings are in compliance with this code of
practice.
Useful Links
Adobe PDF Reader, Autodesk Design Review DXF viewer, Draftsight FREE CAD software
About The Plan

Detailed drawings are provided for components that are commonly manufactured in trailer construction. However, many
trailer component suppliers have a range of standard parts that will do the job just as well. As much detail as possible is given
for purchased parts, considering that there are a wide range of available components on the market. The information given
will assist you with sourcing the hardware you need.
The drawings provide dimensional detail, parts lists and item quantities. Assembly guidelines should be read in conjunction
with the drawings.
Information given in this plan, instructions and drawings comply with Australian regulations. The National Code of Practice –
Building Small Trailers can be downloaded from our website. Please review the code and ensure you trailer complies with the
relevant sections.
So Where do I Start?
We suggest you start by reading this guide completely, and print hard copies of all the drawings, parts list and instructions.
Then, with the parts list as your guide and studying the drawings, plan which parts you will be buying, which parts you will be
manufacturing and which parts you possibly already have. Consider the facilities and equipment at your disposal, your budget
and availability of suppliers when deciding the extent of manufacturing you will be undertaking.
You may then choose to make a few phone calls to local suppliers (or check out some websites) and get an idea of cost and
availability of material and parts you need. It is best to only commence construction when you have all or most of the required
parts on hand. At very least, we suggest you have the suspension, axle, wheels/tyres and chassis steel in your possession before
commencing construction.
You may also choose to approach your trailer project in stages by tackling one major assembly at a time. This not only spreads
the cost over a few weeks (or months) but also places focus on the parts at hand and minimizes the amount of material and
parts lying around your work area.
Whenever in doubt, ask around. You will find many handy blokes out there who have built a trailer at some stage. Trailer parts
suppliers are a great source of information. If you have any queries about the plans or seek clarification, please send us an
email or give us a call.
Safety
Building a trailer involves working with metal, drilling, welding, grinding, painting, heavy lifting and
other potentially harmful activities.
 Ensure that you are familiar with safe working practices of your equipment (welding machine,
drilling machine, grinder, power saw etc) before attempting this project.
 Ensure that you use suitable protective gear such as leather gloves, welding helmet, safety
goggles, hearing protection and protective clothing.
 Find a suitable location to build your trailer – such as a shed or garage.
 Ensure you have sufficient space for the construction activities.
 Remove flammable materials (paints, solvents, fuel containers, gas cylinders)
 Ensure that other people – especially kids - are instructed to stay clear of the project area.
 If in doubt about any safety issues, seek advice before you start.
 Enlist the help of a friend to help you lift and manoeuvre heavy parts & assemblies.
Required Tools
If you are a hands-on person with a fair collection of tools and equipment, you are likely to have all the gear necessary to build
a trailer. Depending on the level of work you wish to perform, below are some of the tools you may need during the
construction of your trailer.
Welding equipment Tape measure Safety & Protective Gear Metal cut-off saw
Angle grinder Various hand tools Work stands (trestles) Large Square
Power Drill G-clamps Painting Equipment Personal Protective Gear
Welding
Trailer construction relies heavily on good strong welds. It is critical to
the safe and reliable operation of the trailer that you are able to apply
consistently strong welds with good penetration. If you doubt your
ability to make a secure weld, seek some advice from a handy mate or
consult some on-line resources. Practice on some scrap off-cuts –
preferably the same material size/thickness you will be building the
trailer with. Test your practice welds by trying to break them apart. Do
not commence construction unless you are confident of your welding abilities.
The drawings use Australian Standards welding symbols to indicate the recommended weld location, size & length of weld.
The symbols are to be used as a guide only. Generally, it is advised to fully weld chassis joints. Body panels can be stitch welded.
If in doubt, apply extra welds. A summary of weld symbols you are likely to find on the drawings is located in the DXF and
Optional Files folder.
Brakes
This trailer is limited to a MAXIMUM ATM of 750kg,
therefore brakes are not required. However, check
your tow vehicle’s un-braked towing capacity, as
smaller vehicles may have un-braked towing
capacities less than 750kg. If you do require trailer
brakes or wish to fit brakes for increased braking
performance and added safety, please refer to our
larger capacity box trailer plans.
IMPORTANT
* GTM = Weight of Load + Weight of trailer on Tyres
(GTM excludes any portion of trailer weight taken up
by the tow vehicle – also called “towball weight”)
Chassis Assembly
The chassis parts are cut and prepared as per the chassis component drawing(s). It is advisable to only commence construction
when you have all the necessary material and parts. Tack-weld all chassis components together first, satisfy yourself that
everything is square and dimensionally to drawing, before commencing welding the chassis in full.
Many professional trailer manufacturers commence construction of the Chassis Assembly upside down. This helps with leveling
of parts (on a smooth flat floor), and makes for easy positioning of drawbar and suspension mounting brackets. However, as it
nears completion the chassis will be heavy and difficult to rotate without the help of lifting equipment. For this reason our
procedure will describe building the chassis the right way up.
1. Refer to the Chassis Assembly drawing. Cut all items listed to length as per the Chassis Component drawings and/or
Material Cut List.
2. Lay the Chassis Rails and Cross Members as shown on a smooth level surface, noting dimensions as per drawing.
Ensure members are SQUARE using a large steel square or similar. Check dimensions, squareness and tack into
position.
It is good practice to tack a job together first, check all

dimensions, squareness and if it’s all correct, then apply full
welds.
3. Position Drawbars as shown. It is important to get the positioning correct to ensure good tracking of the trailer during
towing. Measure from the front of each drawbar to the corners of the chassis and compare Left/Right measurements.
Tack-weld each of the drawbars in place.
4. Whilst positioning the drawbars also place the Coupling Plate in position. Ensure the bolt holes are positioned such
that bolt heads and/or nuts will be clear of the drawbars. Tack-weld the plate in place.
A couple of G-clamps are useful for securing the drawbars while

you establish their position, check dimensions thoroughly.
5. Position and weld the suspension hangers as per the suspension installation instructions. Ensure the axle group center
is as per drawing and the hangers are equal distance from the front cross member.
Ensure suspension brackets are positioned equal distance from front

cross member by comparing Left/Right measurements.
6. Tack-weld Jockey Wheel Mounting Bracket (if welding it) and optional Toolbox Cross Members and associated parts
in place (Ensure that jockey wheel operation is not hindered).
If your jockey wheel mounting bracket is to be bolted to the cross

member, drill the required holes before mounting the cross member.
7. If the jockey wheel is to be welded to the cross member and the weld-on bracket can be detached from the jockey
wheel post, weld it to the cross member now. However, attaching the entire jockey wheel at this stage may hinder
assembly work on the chassis.
8. Position Safety Chain as shown in OT 020 and weld into position. Ensure that the
adjoining link is free to move. Remember to weld around at least 50% of the
circumference of the link. Note minimum safety chain size as listed on OT 020.
Ensure that the chain is suitably designated "ie: 4177-10" - denoting AS4177 and
1000kg ATM.
9. Cap the front open ends of the drawbar using Steel Caps specified (optional).
You may wish to first drill a suitable size hole for running trailer wiring
through one or both of the drawbars.
10. Cut Box Body Frame angle sections and tack-weld into position as per drawing.
11. Check all dimensions thoroughly and weld all previously
tacked welds completely. Take note of weld positions
on drawbar as per drawing OT 020 (shown here in Detail
B). Unless otherwise specified, weld all joints completely
all round.
12. Fit Box Body panels all round. These are either welded
(steel) or bolted/riveted (alloy or composite), which in
the latter case means the chassis could first be painted
or coated as required. See Painting section below.
13. Position and stitch-weld the Floor/Side Panels (if using steel floor sheets), applying welds both above and below the
deck. Typically, place 25mm long welds every 300mm along each plate, cross member and chassis rail joint.
14. Prepare and place Mudguards into position ensuring sufficient clearance for wheels and suspension movement (about
75 to 100mm in most cases).
15. Systematically work through the Chassis Assembly drawing checking each item in the parts list off. Note the quantity
and position of each item.
Suspension, Axle & Wheels (typical fitment)

Now is a good time to fit your suspension and wheels. This will make further work on the trailer safer and a lot easier to move
the trailer around. Consult the fitment instructions that came with your suspension, or ask the supplier for details. The
procedure below describes the typical fitment of a standard shackle mounted leaf spring suspension.
1. Bolt the springs to the mounting brackets (welded to the chassis in Chassis Assembly above), taking care to correctly
position all parts according the supplier’s instructions. Fasten all bolts securely to recommended torque settings.
Hint: Check to see that your axle will fit between the spring and chassis before fastening bolts.
Some axle assemblies pre-fitted with large hubs or drums brakes may be too big.
2. Place the axles on the springs. Most suspension systems have an axle seat that locates between the axle and spring.
3. Assemble the U-Bolts and Fish Plate but do not fasten bolts yet - allow some movement of the axle.
4. Ensure the axles are positioned square to the direction of
travel. Failing to do this will result in your trailer
“wondering or crabbing” behind the tow vehicle and
cause premature tyre wear. One way to ensure a square
axle is to measure from each axle end to the coupling
mount hole or bolt (Dimensions D & S on right hand
image). Both left and right hand measurements should be
identical.
5. Fasten U-Bolts to the supplier’s recommended torque setting.
6. Fit the wheels to the hubs fastening the wheel nuts securely.
7. If you haven't done so already, position the mudguards over the wheels. Set a gap of approx. 75 to 100mm between
top of tyre and underside of mudguard (or enough to allow for suspension travel). Ensure the top surface of the
mudguard it horizontal and tack weld into position.
8. Repeat previous step with opposite side then weld mudguards to side panels and weld all tacks completely.
Painting
It is well worth making a thorough job of painting your trailer. It will not only extend the life of the trailer, but will keep it
looking good for much longer.
Alternatives to painting include powder coating or galvanizing. Both of these involve some extra expense and galvanizing will
require you to drill drain holes in all hollow sections. However, they are both superior coatings to most painting processes and
products – especially galvanizing. Contact your local suppliers of these services for more info.
Before commencing with painting, ensure that all drilling and welding work is complete. Best results are usually achieved with
spray painting, although brush and roller painting would also do the job.
1. If fitted, remove tail lights, wheels, jockey wheel and other items that will prevent thorough coating of bare metal
areas.
Keep the wheels and jockey wheel on the trailer while working on the underside. It’s safer
and easier to move the trailer around. Do not rely on the jockey alone to support the front of
the trailer. Jockey Wheels (especially swivel types) have been known to collapse. Support
the drawbar with a vehicle jack stand or similar.
2. Remove all weld splatter, burrs, and sharp edges. Use a hand file or angle grinder with sand paper disc for best finish.
3. Run a wire brush over all areas – particularly welded areas.
4. Apply generous amounts of paintable sealer (non-silicone, Sikaflex or similar) in gaps – particularly on the underside
corners between trailer floor & chassis frame. Allow to dry.
5. Paint the trailer underside and axle with under-body paint (chassis black). Follow the product instructions.
6. For the rest of the trailer, apply a coat of metal primer and allow drying according the manufacturer’s instructions.
7. Apply at least one coat of the final paint colour, again, following the manufacturer’s instructions.
8. Clean all equipment and brushes using the recommended solvents.
9. Allow sufficient time to dry.
General Assembly
General Assembly is in accordance with the General Assembly drawing(s) with attention to the items listed below. General
Assembly is usually carried out after painting and is essentially the final assembly process of fitting-up your trailer with its
coupling, handbrake (optional), lights & reflectors, electrical wiring, wheels (including spare), emergency brake-away, vehicle
plate, registration plate and other items.
Coupling
Fit a compliant trailer coupling that is rated in excess of the trailer ATM. 2000kg or 3500kg ATM ball couplings are quite common
and affordable. Fit the coupling in accordance with manufacturer/supplier instructions, ensuring correct bolts are used, suitably
fastened and torqued. Check coupling regularly for signs of wear, loss or functionality or loose mounting bolts. For 50mm ball
couplings ensure that ball height (when connected to laden tow vehicle) is between 350mm and 460mm (measured from
ground to center of ball).
Wheels & Tyres

 Tyres must be marked "Made in Australia", have an "E-Mark" or the (USA) DOT marking.
 Speed rating must be at least 120km/h (sometimes indicated by an "L" symbol on the sidewall.
 Total load rating must be greater than the load that the tyres will be carrying with the trailer fully loaded.
 Tyre marking example: LT or P 205/75R15 98Q, where LT = light truck, P = passenger car, 205 = tyre width (mm), 75 =
aspect ratio (height/width), R = radial, 15 = rim diameter (inch), 98 = load rating code (refer to manufacturer or
supplier), Q = speed rating (source: RVM Australia Owner's Manual, 2013)
Jockey Wheel
A suitable Jockey Wheel or stand should be selected with a safe
working load well in excess of the trailer's drawbar weight
when fully loaded. For large heavier trailers jockey wheel are
often impractical, particularly swivel types, and stand (flat plate
base) or removable jockey wheel should be considered. Bolt-on
is preferred to weld on as it is not uncommon to replace a jockey
wheel due to damage or failure. Never rely on a jockey wheel
whilst working under a trailer or changing a flat tyre.
Lights & Reflectors

(see Electrical - Lighting & Wiring below)
Electrical
(see Electrical - Lighting & Wiring below)
Manufacturer's Plate
(see Trailer Registration below)
Electrical – Lighting & Wiring

Trailer wiring is not a difficult task to perform, however, particular attention is necessary to comply with roadworthy standards
and to ensure trouble-free operation of your trailer’s electrical system. If you have any doubt please consult an Automotive
Electrician.
 trailer must be fitted with tail lamps, stop lamps, indicator (turn signal) lamps and a number plate lamp.
 all wiring must be anchored to the chassis at intervals of not more than 600mm along its length;
 all wiring must be insulated at joints;
 all wiring must be located in such a position that it can neither become overheated nor contact moving parts;
 all wiring must be protected from chafing;
 an earth return wire must be provided between the trailer and its hauling vehicle; it is not acceptable to use the trailer coupling
as an earth.
1. Refer to the Electrical Wiring Diagram.

2. Position the trailer’s rear lights as per plan, or if
alternatively, ensuring position complies with VSB1. Drill
all the required holes for feeding electrical cable through.
Remove any sharp edges or burrs that may come into
contact with wiring.
3. Starting with the rear tail lights, connect the wiring as per
diagram taking particular note of wiring colours.
4. Run wiring inside rear cross member through a hole drilled
in proximity of the tail lights.
5. Run cable along inside of Chassis Rail towards the front.
6. Connect each of the red and amber side marker lamps to the brown and white wires.
7. Connect each of the white side marker lamps to the brown and white wires.
8. Feed the cable through the drawbar to the coupling – drilling hole through drawbar cap plates.
9. Allow sufficient length of cable protruding from the front of the drawbar to connect to towing vehicle socket – about
500mm.
10. Connect the electrical connector as per the diagram.
11. Check that wiring is well secured and insulated at all joints.
12. Test the electrical system using a trailer wiring tester (available from automotive spares supplier), multi-meter or
connecting to tow vehicle.
13. Fit white (forward), amber (side) and red (rear) reflectors as per VSB1 section 9.8
Trailer Registration
Check registration requirements with your local registration authority. Registration requirements and procedures vary from
state to state and trailer type, use, and ATM.
 You will need a Manufacturer’s Plate (Trailer Plate) which you can often buy from an Automotive Spares Supplier or
directly from the registration authority. The plate contains relevant information such as Manufacturer’s Name, Vehicle
Identification Number (VIN), Date of Manufacture, ATM, Tyre Ratings, Suspension Ratings etc.
 The Manufacturer’s Plate is often mounted on the drawbar. It should be attached by permanent means - usually by
using pop rivets or hammer drive screws.
 Most registration authorities have comprehensive web sites from which you can get all relevant and up to date
information as well as download application forms.
 See the registration page on our website for more information and links.
PREPARED BY
OKAJARO Pty Ltd
trading as TrailerPlans.com.au
ACN 147 897 961
Brisbane, Australia Tel: 0408 112 604
info@trailerplans.com.au
© Copyright protected by TrailerPlans.com.au
6 5 4 3 2 1
5x3 BOX TRAILER - GENERAL ASSEMBLY MAXIMUM TRAILER RATINGS

ITEM RATING (kg)
ATM 750
D 21 20 D
GTM 660
22 TARE 225
LOAD ± 525
BALL LOAD ± 90

19 TARE, LOAD CAPACITY and BALL LOAD are
Could also use an automotive estimated values only. Actual weights may vary.
style under-body chain winch

15
DETAIL B 16
SPARE WHEEL MOUNTING 17
UNDER TRAILER
2
6
7
C DETAIL A 5 5
C
REAR VIEW OF TRAILER
3
23
PARTS LIST 4
ITEM QTY PART NUMBER DESCRIPTION
1 1 BT 005 CHASSIS ASSEMBLY
2 1 BT 011 BOX BODY ASSEMBLY
3 1 BT 013 TOOLBOX ASSEMBLY 8
4 2 M290 MUDGUARD 14x10 SINGLE FORMED
5 4 LT 246 ANGLE TRIM BOX 1
6 1 UNBRAKED AXLE 45SQx1200 F-F
B 7 2 SINGLE AXLE LEAF SUSPENSION KIT B
12
8 3 WHEEL & TYRE 195/70R15 (OR SIMILAR)
9 1 MTNG BRAKET J/WHEEL 13
10 1 8" JOCKEY WHEEL (or similar)
11 1 COUPLING TO ADR
12 4 M12 NYLOC NUT M12 NYLOC 18
24 10
13 2 M12x35 BOLT M12x35 GR8.8 Z/P IMPORTANT NOTES
14 2 60 B M12 x 70 BOLT 8.8 M12 x 70 Z/P 1. See Sheet 2 for dimensioned General Arrangement. 9
15 1 LT 250 SPARE WHEEL SUPPORT PLATE 2. Vehicle Plate (VIN Plate) to be permanently fixed as per VSB01, section 7.
3. Tyre, suspension and axle rating not less than GTM.
16 1 M12 WING NUT M12 WING NUT Z/P 4. Lighting and electrical installation strickly as per VSB01 sec 13 and 14. 14
17 1 LYNCH PIN 6mm 5. All fasteners minimum class 8.8 zinc plated or similar.
11
18 2 REFLECTOR CLEAR
19 2 REFLECTOR RED
A 20 1 NUMBER PLATE LIGHT LED DXF FILES: Designed by Approved by © Copyright protected. Do not distribute Date DO NOT A
Selected sheets in this drawing set are available in DvD TP without written permission. 10/07/2016 SCALE
21 1 REGISTRATION PLATE DXF format for use by laser or profile cutting
22
23
2
2
LED TAILIGHT UNIT
REFLECTOR AMBER
sevice. Download them free from
www.trailerplans.com.au/downloads
TrailerPlans .com.au 5x3 BOX TRAILER
brought to you by: OKAJARO Pty Ltd Revision Sheet
(password jtypks2) Dwg No: BT53
24 4 RHS END CAP 50x50 ACN: 147 897 961 1/7
6 5 4 3 2 1
6 5 4 3 2 1
GENERAL DIMENSIONS
400 60
D NOTES: D
1. * Check clearance between top of wheel & mudguard for sufficient suspension
travel.
2. Wheel & Tyre shown: 195/70R15
3. Bed height subject to wheel/tyre size, axle selection and suspension setup.
3. Lighting and electrical installation strickly as per VSB01 sec 13 and 14.
4. Floor Sheets, Box Panels and Mudguard (if welded) to be stitched minimum 25
long at 200 intervals all round.
900
DXF FILES:
This drawing is available in DXF format for use by
laser or profile cutting sevice. Download it free
from www.trailerplans.com.au/downloads
(password btfws8)
C C
ALLOY TOOLBOX
(OPTIONAL)
1086 (DRAWBAR) 1500 1400
SEE
NOTE 4
B B
278 *
969
472
454
1210 (TRACK WIDTH)
914 (FRONT SECTION) 586 (REAR OVERHANG)
A Designed by Approved by © Copyright protected. Do not distribute Date DO NOT A

2666 (TOTAL/OVERALL LENGTH)
without written permission. 7/10/2016
DvD TP SCALE
TrailerPlans.com.au 5x3 BOX TRAILER

ACN: 147 897 961 Dwg No: BT53 2/7
6 5 4 3 2 1
6 5 4 3 2 1
CHASSIS ASSEMBLY
1500 2
D 400 60 D
425 450 425 WELD SIDES
OF HANGERS 5
ONLY - TYP 3
SEE DETAIL B ON DRAWING
OT 020 FOR DRAWBAR WELDING 6
7
10
8
1
900
30°
11
WELD ALL
C ROUND 4 C
TOOLBOX SUPPORTS TYP
ONLY REQUIRED IF 9
FITTING TOOLBOX
DRAWBAR FLUSH WITH
1000 (DRAWBAR) 500 (DRAWBAR) OUTER FACE OF CHASSIS
BT 005 - CHASSIS ASSEMBLY 1500x900 (5x3ft)
900 (CENTER OF AXLE)
QTY: 1
AXLE DETAILS:
FACE TO FACE LENGTH: 1180 (using 195/70R15 wheel
and tyres with zero offset)
263 710 * (see 09 GPA 360 - AXLE SELECTION for more detail)
B B
IMPORTANT NOTES:
PARTS LIST 1. Weld all joints completely all round unless otherwise specified.
ITEM CUT LENGTH QTY TOT LENGTH PART No OR SECTION DESCRIPTION 2. Use minimum 350MPa construction grade Rectangular or Square Hollow Section
(SHS or RHS) as advised.
1 1400 2 2800 50x50x3.0 SHS - 1400 CHASSIS RAIL - AS1163 C350L0 3. Wall thickness minimum 3mm unless otherwise stated.
2 900 2 1800 50x50x3.0 SHS - 900 END CROSS MEMBER - AS1163 C350L0 4. See TB 025 for suspension mounting detail.
3 800 2 1600 50x50x3.0 SHS - 800 CROSS MEMBER - AS1163 C350L0 5. See OT 020 for Drawbar, Safety Chain, Coupling Plate and Jockey Wheel welding details.
6. See Complete Parts List for part/drawing number cross reference.
4 1552 2 3105 50x50x3.0 SHS - 1552 DRAWBAR - AS1163 C350L0 7. See further drawings for selected component detail.
5 425 1 425 50x50x3.0 SHS - 425 SPARE SUPPORT - AS1163 C350L0 8. * Typical values given. Check suspension installation instructions.
6 498 1 498 25x25x2.5 SHS - 498 TOOLBOX SUP 1 - AS1163 C350L0
A 7 298 1 298 25x25x2.5 SHS - 298 TOOLBOX SUP 2 - AS1163 C350L0
Designed by Approved by © Copyright protected. Do not distribute Date DO NOT A
DvD TP without written permission. 10/07/2016 SCALE
8 1 GPC 110 2T COUPLING MOUNT PLATE
9
10
1
2
SAFETY CHAIN TO AS4177
SINGLE AXLE WELD-ON KIT
11 1 M12 x 120 HEX BOLT M12x120 ACN: 147 897 961 Dwg No: BT53 3/7
6 5 4 3 2 1
6 5 4 3 2 1
BOX BODY FRAME & ASSEMBLY 1

5
3
2
GENERAL DESCRIPTION: 6
D The Box Body consists of a steel frame fabricated using 25x25 SHS D
or Angle sections welded directly onto the chassis. The frame
supports the lid hinges as well as gas strut mounts and is covered
using panels which are either welded (steel) or screwed/riveted
(aluminium).
1500 4
BT 011 - BOX BODY ASSEMBLY

QTY: 1
C C
PARTS LIST
ITEM CUT LENGTH QTY TOT LENGT PART NUMBER DESCRIPTION
1 500 6 3000 ANGLE 30x30x3 - 500 FRAME UPRIGHT
900
2 1500 2 3000 ANGLE 30x30x3 - 1500 FRAME SIDE RAIL
3 900 2 1800 ANGLE 30x30x3 - 900 FRAME FRONT/REAR RAIL
4 2 BT 015 BOX PANEL SIDE
5 2 BT 016 BOX PANEL FRONT/REAR
6 1 BT 017 BOX PANEL FLOOR
IMPORTANT NOTES:
1. Weld all joints completely all round unless otherwise specified.
B 2. Use minimum 350MPa construction grade Rectangular or Square Hollow Section B
900 (SHS or RHS) as advised.
3. Wall thickness minimum 3mm unless otherwise stated.
4. See material cut list for total cut length by trailer size.
5. Floor sheet fitted after frame assembly onto chassis and notched out around Uprights
as required
500
A Designed by Approved by © Copyright protected. Do not distribute Date DO NOT A


ACN: 147 897 961 Dwg No: BT53 4/7
6 5 4 3 2 1
6 5 4 3 2 1
BOX BODY PANELS

900
D D
1500
500
900
BT 016 - BOX PANEL FRONT/REAR

C MATL: SEE NOTE C
QTY: 2
500
BT 017 - BOX PANEL FLOOR
MATL: SEE NOTE
QTY: 1
B B
1500
MATERIAL:
FLOOR SHEETS CAN BE EITHER STEEL (FROM 2mm) OR ALLOY (FROM BT 015 - BOX PANEL SIDE
3mm) IN SMOOTH OR CHEQUER PLATE. MATL: SEE NOTE
ROOF, BODY AND LOWER PANELS CAN BE EITHER STEEL (FROM QTY: 2
1.2mm), ALLOY (FROM 2mm) OR COMPOSITE (FROM 3mm).
A DXF FILES: Designed by Approved by © Copyright protected. Do not distribute Date DO NOT A
This drawing is available in DXF format for use by DvD TP without written permission. 10/07/2016 SCALE
(password btfws8)
ACN: 147 897 961 Dwg No: BT53 5/7
6 5 4 3 2 1
6 5 4 3 2 1
NOSE CONE ASSEMBLY & PARTS LIST

D D
9 13
11
10 12
LID FRAME
12 BOX (NOSE CONE) FRAME (SHS or ANGLE)
(ANGLE & FLAT BAR)
52°
900
8
7
6
4
C C
400
1
412
14
3
700
38
5 2 400
340
B B
PARTS LIST
ITEM CUT LENGTH QTY TOT LENGTH PART NUMBER DESCRIPTION
1 900 2 1800 ANGLE 30x30x3 - 900 BOX FRAME REAR
2 412 4 1649 ANGLE 30x30x3 - 412 BOX FRAME SIDE
IMPORTANT NOTES:
3 700 2 1400 ANGLE 30x30x3 - 700 BOX FRAME FRONT 1. WELD ALL JOINTS COMPLETELY ALL ROUND UNLESS OTHERWISE SPECIFIED.
4 340 8 2720 FLAT 30 x 5 - 340 BOX FRAME UPRIGHT 2. USE MINIMUM 350MPA CONSTRUCTION GRADE RECTANGULAR OR SQUARE
5 2 BT 120 NOSE CONE PANEL BASE/TOP HOLLOW SECTION (SHS OR RHS) AS ADVISED.
6 1 BT 121 NOSE CONE PANEL FRONT 3. WALL THICKNESS MINIMUM 3mm UNLESS OTHERWISE STATED.
7 1 BT 122 NOSE CONE PANEL REAR 4. SECURE NOSE CONE ONTO TRAILER THROUGH FRAME
8 2 BT 123 NOSE CONE PANEL SIDE
9 700 1 700 SHS 30x30x1.6 - 700 LID FRAME FRONT
A 10 412 2 825 SHS 30x30x1.6 - 412 LID FRAME SIDE
Designed by Approved by © Copyright protected. Do not distribute Date DO NOT A
11 900 1 900 SHS 30x30x1.6 - 900 LID FRAME REAR
12
13
1
2
X109HT
UES 7011
RUBBER SEAL X109HT NOSE CONE
WELD-ON BULLET HINGE
14 1 PULL LATCH LOCKABLE 2168 ACN: 147 897 961 Dwg No: BT53 6/7
6 5 4 3 2 1
6 5 4 3 2 1
NOSE CONE PANELS

700
700
D D
76
°
400
400
C 900 C
BT 121 - NOSE CONE PANEL FRONT
MATL: SEE NOTE
BT 120 - NOSE CONE PANEL BASE/LID
QTY: 1
MATL: SEE NOTE
QTY: 2
900
412
B B
400
400
BT 122 - NOSE CONE PANEL REAR BT 123 - NOSE CONE PANEL SIDE
MATL: SEE NOTE MATL: SEE NOTE
QTY: 1 QTY: 2
A DXF FILES: Designed by Approved by © Copyright protected. Do not distribute Date DO NOT A
MATERIAL: This drawing is available in DXF format for use by DvD TP without written permission. 10/07/2016 SCALE
PANELS CAN BE EITHER STEEL (FROM 1.2mm),
ALLOY (FROM 2mm) OR COMPOSITE (FROM 3mm).
(password btfws8)
ACN: 147 897 961 Dwg No: BT53 7/7
6 5 4 3 2 1
COMPLETE PARTS LIST TrailerPlans.com.au
Rev 0
5x3 BOX TRAILER 04/10/2016
ITEM QTY PART NUMBER DESCRIPTION LENGTH/SIZE TOT LENGTH SUPPLIER END CONDITION COST
GENERAL ASSEMBLY - BT53
1 1 BT 005 CHASSIS ASSEMBLY FABRICATE/DIY
2 1 BT 011 BOX BODY ASSEMBLY FABRICATE/DIY
3 1 BT 013 TOOLBOX ASSEMBLY FABRICATE/DIY
4 2 M290 MUDGUARD 14x10 SINGLE FORMED FABRICATE/DIY OR PURCHASE
5 4 LT 246 ANGLE TRIM BOX STEEL SUPPLIER/DIY
6 1 UNBRAKED AXLE 45SQx1200 F-F TRAILER PARTS
7 2 SINGLE AXLE LEAF SUSPENSION KIT TRAILER PARTS
8 3 WHEEL & TYRE 195/70R15 (OR SIMILAR) WHEEL & TYRE DEALER
9 1 MTNG BRAKET J/WHEEL TRAILER PARTS
10 1 8" JOCKEY WHEEL (or similar) TRAILER PARTS
11 1 COUPLING TO ADR TRAILER/AUTO PARTS/HARDWARE
12 4 M12 NYLOC NUT M12 NYLOC TRAILER/AUTO PARTS/HARDWARE
13 2 M12x35 BOLT M12x35 GR8.8 Z/P TRAILER/AUTO PARTS/HARDWARE
14 2 60 B M12 x 70 BOLT 8.8 M12 x 70 Z/P TRAILER/AUTO PARTS/HARDWARE
15 1 LT 250 SPARE WHEEL SUPPORT PLATE TRAILER/AUTO PARTS/HARDWARE
16 1 M12 WING NUT M12 WING NUT Z/P TRAILER/AUTO PARTS/HARDWARE
17 1 LYNCH PIN 6mm TRAILER/AUTO PARTS/HARDWARE
18 2 REFLECTOR CLEAR TRAILER/AUTO PARTS/HARDWARE
19 2 REFLECTOR RED TRAILER/AUTO PARTS/HARDWARE
20 1 NUMBER PLATE LIGHT LED TRAILER/AUTO PARTS/HARDWARE
21 1 REGISTRATION PLATE TRAILER/AUTO PARTS/HARDWARE
22 2 LED TAILIGHT UNIT TRAILER/AUTO PARTS/HARDWARE
23 2 REFLECTOR AMBER TRAILER/AUTO PARTS/HARDWARE
24 4 RHS END CAP 50x50 TRAILER/AUTO PARTS/HARDWARE
CHASSIS ASSEMBLY - BT 005

1 2 50x50x3.0 SHS - 1400 CHASSIS RAIL - AS1163 C350L0 1,400 2,800 STEEL SUPPLIER SQUARE
2 2 50x50x3.0 SHS - 900 END CROSS MEMBER - AS1163 C350L0 900 1,800 STEEL SUPPLIER SQUARE
3 2 50x50x3.0 SHS - 800 CROSS MEMBER - AS1163 C350L0 800 1,600 STEEL SUPPLIER SQUARE
4 2 50x50x3.0 SHS - 1552 DRAWBAR - AS1163 C350L0 1,552 3,105 STEEL SUPPLIER PARTIAL 45° FRONT/REAR
5 1 50x50x3.0 SHS - 425 SPARE SUPPORT - AS1163 C350L0 425 425 STEEL SUPPLIER SQUARE
6 1 25x25x2.5 SHS - 498 TOOLBOX SUP 1 - AS1163 C350L0 498 498 STEEL SUPPLIER TO SUIT DRAWBAR ANGLE
7 1 25x25x2.5 SHS - 298 TOOLBOX SUP 2 - AS1163 C350L0 298 298 STEEL SUPPLIER TO SUIT DRAWBAR ANGLE
8 1 GPC 110 2T COUPLING MOUNT PLATE STEEL SUPPLIER/DIY DRILL
9 1 SAFETY CHAIN TO AS4177 TRAILER/AUTO PARTS
10 2 SINGLE AXLE WELD-ON KIT TRAILER PARTS
11 1 M12 x 120 HEX BOLT M12x120 TRAILER/AUTO PARTS/HARDWARE
Page 1 of 2
COMPLETE PARTS LIST TrailerPlans.com.au
Rev 0
ITEM QTY PART NUMBER DESCRIPTION LENGTH/SIZE TOT LENGTH SUPPLIER END CONDITION COST
BOX BODY ASSEMBLY - BT 011
1 6 ANGLE 30x30x3 - 500 FRAME UPRIGHT 500 3,000 STEEL SUPPLIER SQUARE
2 2 ANGLE 30x30x3 - 1500 FRAME SIDE RAIL 1,500 3,000 STEEL SUPPLIER MITRE 45°
3 2 ANGLE 30x30x3 - 900 FRAME FRONT/REAR RAIL 900 1,800 STEEL SUPPLIER MITRE 45°
4 2 BT 015 BOX PANEL SIDE 1500x500 STEEL SUPPLIER
5 2 BT 016 BOX PANEL FRONT/REAR 900x500 STEEL SUPPLIER
6 1 BT 017 BOX PANEL FLOOR 1500x900 STEEL SUPPLIER
NOSE CONE (TOOLBOX) ASSEMBLY - BT 013

1 2 ANGLE 30x30x3 - 900 BOX FRAME REAR 900 1,800 STEEL SUPPLIER MITRE 52°
2 4 ANGLE 30x30x3 - 412 BOX FRAME SIDE 412 1,649 STEEL SUPPLIER MITRE 52° & 38°
3 2 ANGLE 30x30x3 - 700 BOX FRAME FRONT 700 1,400 STEEL SUPPLIER MITRE 38°
4 8 FLAT 30 x 5 - 340 BOX FRAME UPRIGHT 340 2,720 STEEL SUPPLIER SQUARE
5 2 BT 120 NOSE CONE PANEL BASE/TOP 900/700x400 STEEL SUPPLIER
6 1 BT 121 NOSE CONE PANEL FRONT 700x400 STEEL SUPPLIER
7 1 BT 122 NOSE CONE PANEL REAR 900x400 STEEL SUPPLIER
8 2 BT 123 NOSE CONE PANEL SIDE 412x400 STEEL SUPPLIER
9 1 SHS 30x30x1.6 - 700 LID FRAME FRONT 700 700 STEEL SUPPLIER MITRE 38°
10 2 SHS 30x30x1.6 - 412 LID FRAME SIDE 412 825 STEEL SUPPLIER MITRE 52° & 38°
11 1 SHS 30x30x1.6 - 900 LID FRAME REAR 900 900 STEEL SUPPLIER MITRE 52°
12 1 X109HT RUBBER SEAL X109HT NOSE CONE APPROX 2.5m TRAILER/AUTO PARTS/HARDWARE
13 2 UES 7011 WELD-ON BULLET HINGE TRAILER/AUTO PARTS/HARDWARE
14 1 PULL LATCH LOCKABLE 2168 TRAILER/AUTO PARTS/HARDWARE
OTHER
1
2
4
5
6
7
8
Page 2 of 2
MATERIAL CUT LIST TrailerPlans.com.au
Rev 0
QTY PART NUMBER DESCRIPTION LENGTH/SIZE TOT LENGTH SUPPLIER END CONDITION COST
50x50x3 SHS 350MPa
2 50x50x3.0 SHS - 1400 CHASSIS RAIL - AS1163 C350L0 1,400 2,800 STEEL SUPPLIER SQUARE
2 50x50x3.0 SHS - 900 END CROSS MEMBER - AS1163 C350L0 900 1,800 STEEL SUPPLIER SQUARE
2 50x50x3.0 SHS - 800 CROSS MEMBER - AS1163 C350L0 800 1,600 STEEL SUPPLIER SQUARE
2 50x50x3.0 SHS - 1552 DRAWBAR - AS1163 C350L0 1,552 3,105 STEEL SUPPLIER PARTIAL 45° FRONT/REAR
1 50x50x3.0 SHS - 425 SPARE SUPPORT - AS1163 C350L0 425 425 STEEL SUPPLIER SQUARE
9,730
25x25x2.5 SHS 350MPa

1 25x25x2.5 SHS - 498 TOOLBOX SUP 1 - AS1163 C350L0 498 498 STEEL SUPPLIER TO SUIT DRAWBAR ANGLE
1 25x25x2.5 SHS - 298 TOOLBOX SUP 2 - AS1163 C350L0 298 298 STEEL SUPPLIER TO SUIT DRAWBAR ANGLE
1 25x25x2.5 SHS - 700 LID FRAME FRONT (could also use 30x30 SHS) 700 700 STEEL SUPPLIER MITRE 38°
2 25x25x2.5 SHS - 412 LID FRAME SIDE (could also use 30x30 SHS) 412 825 STEEL SUPPLIER MITRE 52° & 38°
1 25x25x2.5 SHS - 900 LID FRAME REAR (could also use 30x30 SHS) 900 900 STEEL SUPPLIER MITRE 52°
3,221
30x30x3 ANGLE
6 ANGLE 30x30x3 - 500 FRAME UPRIGHT 500 3,000 STEEL SUPPLIER SQUARE
2 ANGLE 30x30x3 - 1500 FRAME SIDE RAIL 1,500 3,000 STEEL SUPPLIER MITRE 45°
2 ANGLE 30x30x3 - 900 FRAME FRONT/REAR RAIL 900 1,800 STEEL SUPPLIER MITRE 45°
2 ANGLE 30x30x3 - 900 BOX FRAME REAR 900 1,800 STEEL SUPPLIER MITRE 52°
4 ANGLE 30x30x3 - 412 BOX FRAME SIDE 412 1,649 STEEL SUPPLIER MITRE 52° & 38°
2 ANGLE 30x30x3 - 700 BOX FRAME FRONT 700 1,400 STEEL SUPPLIER MITRE 38°
12,649
MISCELLANEOUS SECTIONS
8 FLAT 30 x 3 - 340 BOX FRAME UPRIGHT 340 2,720 STEEL SUPPLIER SQUARE
2,720
PANELS & SHEET (MINIMUM 2mm STEEL SHEET OR 3mm ALUMINIUM)

1 GPC 110 2T COUPLING MOUNT PLATE (SEE DRAWING) STEEL SUPPLIER/DIY DRILL
2 BT 015 BOX PANEL SIDE 1500x500 STEEL SUPPLIER
2 BT 016 BOX PANEL FRONT/REAR 900x500 STEEL SUPPLIER
1 BT 017 BOX PANEL FLOOR 1500x900 STEEL SUPPLIER
2 BT 120 NOSE CONE PANEL BASE/TOP 900/700x400 STEEL SUPPLIER
1 BT 121 NOSE CONE PANEL FRONT 700x400 STEEL SUPPLIER
1 BT 122 NOSE CONE PANEL REAR 900x400 STEEL SUPPLIER
2 BT 123 NOSE CONE PANEL SIDE 412x400 STEEL SUPPLIER
SHS = Square Hollow Section
Page 1 of 1
6 5 4 3 2 1
SUSPENSION INSTALLATION Load Area

710**
50* Min.
D
Single D
c e n t r e o f lo a d a r e a
D
Axle
wh e e l c e n t r e
S
T o s u i t wh e e l
& t y r e s iz e
D 365**
S
Measure dimensions "D" and

(front load space)* (rear overhang)*
C "S" on LH & RH and ensure C
that they are equal.
Load Area
840** 840**
What the law says: 100* Min.
Rear overhang must not exceed the lesser of 3.7 Tandem
metres or the front load space. (VSB par 21.2)
Axle
c e n t r e o f lo a d a r e a
B B
a x le g r o u p c e n t r e
IMPORTANT: ±965**
* See Chassis Assembly or GA drawing supplied. (front load space)* (rear overhang)*
** May vary depending on suspension make and model.
1. Suspension shown is typical of shackle mounted leaf sprung
trailer suspension.
2. Rear overhang position is important as it is not only required
by law, but also provides for a well balanced trailer and
improved road handling characteristics.
A Designed by Checked by Approved by Date Created Material
A
3. Rule of Thumb: For each foot (305mm) of load area, move the DvD 07-Apr-13
axle center back 1" (25mm) from center of load area. Consider the
load you will be carrying and how it will be distributed. Also consider TrailerPlans.com.au SUSPENSION INSTALLATION
brought to you by OKAJARO Pty Ltd Edition Sheet
your tow vehicle's max vertical towbar load capacity. © Copyright protected by
TB 025
TrailerPlans ACN: 147 897 961 2 1/1
6 5 4 3 2 1
6 5 4 3 2 1
CHASSIS FIXTURES 5
5 5 50 Max.
D Ensure holes are D

clear from drawbar
to allow bolt fitment 5

NOTE: Weld cover
plates to drawbar first,
then weld coupling

plate to to cover plates
DETAIL A - Coupling Plate

A
SIDE
Do not weld 5 ONLY
C C
across top
B DRAWBAR of drawbar
SIDE
5 ONLY
D C 5
IF NOT 5
DETAIL B - Drawbar Welding
BOLTING 5 If not welding, drill & NOTE: Welding across top of drawbar is generally not
B bolt securely on center advised as it could lead to weakening of the drawbar B
of drawbar section.
CAUTION: Safety chain

NOTE: Bracket can be bolted or
attachment points should not
welded to drawbar - usually on
come into contact with road
the driver's side of the trailer DETAIL D Weld at least surface when the trailer is
50% of link 5
Jockey Wheel Mount disconnected.
TIP: Allow sufficient length of

Safety Chain Size DETAIL C Safety Chain chain (you can always cut a few
ATM (kg) Chain Marking Link Diam (mm) links off later if it's too long)
0 to 1000 4177-10 6.3
Up to 1600 4177-16 8 Designed by Checked by Date
A Up to 2500 4177-25 10 © Copyright protected A
DvD 17-Apr-13
Up to 3500 4177-35 13
IMPORTANT: Trailer must be fitted with minimum safety
chain size as above. Use only Australian Standard chain
TrailerPlans.com.au CHASSIS FIXTURES
marked "4177-XX" every 4th link (AS4177.4) ACN: 147 897 961 Dwg No: OT 020 03 1/1
6 5 4 3 2 1
6 5 4 3 2 1
AXLE SELECTION
D D
TT = Tip to Tip
Axle Dimensions
Dimension Name Description
Tip to Tip Total length of axle from end
TT
FF = Face to Face to end
Distance from one wheel face
FF Face to Face to the other (track width)
CW = Chassis Width CF Distance between outside of
CW Chassis Width
chassis rails
TC Chassis to Distance from outside of
CF
Face chassis rail to wheel face
Distance between outside of
TC Tyre Clearance
chassis rail to inside wall of tyre
Steel section of axle (45
AS Axle Section square, 50 rounds etc)
TW Tread Width Tread width of tyre
C C
BS Back Space Distance from inside tyre wall
to wheel face
AS
Axle Selection
Before sourcing an axle you will need to decide on the
following:
- Trailer ATM/GTM
- Single or Tandem axle
- Choice of brake type
- Tyre size and stud pattern
B B
BS
Based on this information the suspension supplier will
recommend a minimum axle section, hub/disc/drum size,
TW
bearing size an axle length for your trailer.
Axle Length (Face to Face)
FF = CW + (2 x TC) + (2 x BS)
where:
TC is minimum 45mm
BS is measured or calculated from tyre size
Example:
For a CW of 1200mm, Date
A Designed by Checked by A
Tyre size 205/75R15 (no offset) © Copyright protected
DvD 12-Jun-11
FF = 1200 + (2 x 45) + (205) = 1495mm TrailerPlans.com.au AXLE SELECTION

ACN: 147 897 961 GPA 360 1/1
6 5 4 3 2 1
6 5 4 3 2 1
Coupling Mounting Plates

D D
75 8
n 1
3
C C
220
185
135
102
3
n1
BT 105 - Coupling Mount Plate 2 hole

B Material: 75x8 Mild Steel Flat Bar or similar B
54
90
GP 150 - Universal 4 Bolt Coupling Plate

Material: 90x8 Mild Steel Flat Bar or similar
IMPORTANT:
OVERHANG FROM FRONT OF DRAWBAR TO
FRONT OF PLATE MAXIMUM 50mm
A Designed by Checked by
© Copyright protected
Date
A
DvD 16-Apr-13
TrailerPlans.com.au Coupling Mounting Plates

brought to you by: OKAJARO Pty Ltd Edition Sheet
ACN: 147 897 961 GP 020 2 1/1
6 5 4 3 2 1
6 5 4 3 2 1
WELD SYMBOL GUIDE

The Weld Symbol Intermittent Welds
Assembly drawings will generally contain a number of weld
Weld symbols are to Australian Standard AS 1101.3 symbols giving guidance as to the position, type, size, length
D as summarized on this drawing. The vast majority of D
and pitch of welds
welds used in our plans are fillet welds. This page
only covers the ones you are likely to encounter WHERE:
during your build. Please consult AS 1101.3 or online S = Size of weld

L = Length of weld
resources for a more comprehensive weld symbol
P = Pitch of intermittent welds
guide if needed. NOTES = Further details about weld
Arrow Side = Weld on arrow side of parts

Unless otherwise specified on drawings, all Other Side = Weld on opposite side of arrow
welds on our plans are minimum 5mm in size
and welded all round.
Size & Position Weld Length
C Drawing symbols indicates 8mm C

fillet weld on arrow side Drawing symbol indicates fillet welds 50 long at 125 pitch
Drawing indicates two
S=8 arrow side and other side (no sizes given). Also includes text
symbols each with a fillet weld
Type = Fillet Weld (triangle) "See note" directing reader in this example to check drawing
on arrow side (no sizes given)
Position = Arrow Side notes.
S = min. 5mm
S = min. 5mm
Type = Fillet Weld (triangle)
Position = Arrow Side
Position = Arrow & Other Sides
Length = full length weld
Length = 50
along indicated edge
Pitch = 125
Basic Weld Symbols
Drawing symbols indicates two Square-Butt Weld, used

12mm fillet welds on arrow side generally to weld two plates side
and other side by side
S = 12
B Type = Fillet Weld (triangle) Drawing indicates two V-Butt Weld, used generally to B
Position = Arrow & Other Side symbols, one with a 20 long weld two plates side by side with
fillet weld and another with 40 bevelled "V" edges
long fillet weld - both on
arrow side (no sizes given)
S = min. 5mm
Type = Fillet Weld (triangle) Plug or Slot Weld, used
Position = Arrow Side generally to weld into a drilled
Length = weld minimum hole or slot
length as per symbol
Fillet Weld, used commonly to
weld material at square angles
Drawing symbol indicates fillet
All Round Weld weld on arrow side all round
(no sizes given)
S = min. 5mm
Position = All Round the
joint Designed by Checked by Date
A © Copyright protected A
Most common weld in DvD 24-Apr-13
Drawing Interpretation
trailer manufacture and
the default if no other
weld is specified.
TrailerPlans.com.au WELD SYMBOL GUIDE
ACN: 147 897 961 Dwg No: GPW 100 1 1/1
6 5 4 3 2 1
GP 155 - RHS STEEL END CAPS
50 50 5 50 5
50
5
5
45°
45°
75
100
66
10
2
50
GP 155-3 - STEEL CAP 75x50

Material: 5mm M/S Plate
75
Qty: as per drawing GP 155-4 - STEEL CAP 100x50
GP 155-1 - STEEL CAP 100x50x45° Qty: as per drawing
Qty: as per drawing
GP 155-2- STEEL CAP 150x50x45°

Qty: as per drawing 50 5
45°
10
4
67
45°
52
38
GP 155-9 - STEEL CAP 67x50
77
Qty: as per drawing

5 50
GP 155-6 - STEEL CAP 75x50x45DEG

5 Material: 5mm M/S Plate NOTES:
75
Qty: as per drawing 1. Use Mild Steel (M/S) plate or flat steel bar as required.
GP 155-5 - STEEL CAP 150x75x45DEG 2. See relevant assembly drawing for required quantity.
Qty: as per drawing
Drawn by Date © Copyright protected. This drawing is the property of Okajaro Pty Ltd. It DO NOT
4/02/2019 may not be copied, published or distributed without written permission. SCALE
DvD
UNLESS OTHERWISE SPECIFIED Title
•
•
MATERIAL GRADE MINIMUM 350MPa
RHS/SHS/CHS WALL THICKNESS MINIMUM 3mm
•
•
WELD JOINTS ALL ROUND
DIMENSIONS IN mm
TrailerPlans .com.au
Dwg No
RHS STEEL END CAPS
Revision Sheet
brought to you by OKAJARO Pty Ltd
• FASTENERS MINIMUM CLASS 8.8 OR GRADE • TOLERANCE ±1mm ACN: 147 897 961
GP 155 1 1/1
E info@trailerplans.com.au W www.trailerplans.com.au

18BT53 5X3 Box Trailer Drawings PDF

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ASSEMBLY GUIDE - 5x3 BOX TRAILER

750kg ATM UNBRAKED 5x3 BOX TRAILER

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About The Plan

It is good practice to tack a job together first, check all

A couple of G-clamps are useful for securing the drawbars while

Ensure suspension brackets are positioned equal distance from front

If your jockey wheel mounting bracket is to be bolted to the cross

Suspension, Axle & Wheels (typical fitment)

Wheels & Tyres

Lights & Reflectors

Electrical – Lighting & Wiring

1. Refer to the Electrical Wiring Diagram.

5x3 BOX TRAILER - GENERAL ASSEMBLY MAXIMUM TRAILER RATINGS

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style under-body chain winch

1086 (DRAWBAR) 1500 1400

1210 (TRACK WIDTH)

914 (FRONT SECTION) 586 (REAR OVERHANG)

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TrailerPlans.com.au 5x3 BOX TRAILER

BOX BODY FRAME & ASSEMBLY 1

BT 011 - BOX BODY ASSEMBLY

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TrailerPlans.com.au 5x3 BOX TRAILER

BOX BODY PANELS

BT 016 - BOX PANEL FRONT/REAR

NOSE CONE ASSEMBLY & PARTS LIST

NOSE CONE PANELS

CHASSIS ASSEMBLY - BT 005

NOSE CONE (TOOLBOX) ASSEMBLY - BT 013

25x25x2.5 SHS 350MPa

PANELS & SHEET (MINIMUM 2mm STEEL SHEET OR 3mm ALUMINIUM)

SHS = Square Hollow Section

SUSPENSION INSTALLATION Load Area

Measure dimensions "D" and

D Ensure holes are D

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then weld coupling

DETAIL A - Coupling Plate

CAUTION: Safety chain

TIP: Allow sufficient length of

FF = 1200 + (2 x 45) + (205) = 1495mm TrailerPlans.com.au AXLE SELECTION

Coupling Mounting Plates

BT 105 - Coupling Mount Plate 2 hole

GP 150 - Universal 4 Bolt Coupling Plate

TrailerPlans.com.au Coupling Mounting Plates

WELD SYMBOL GUIDE

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Arrow Side = Weld on arrow side of parts

Size & Position Weld Length

C Drawing symbols indicates 8mm C

Basic Weld Symbols

Drawing symbols indicates two Square-Butt Weld, used

GP 155-3 - STEEL CAP 75x50

GP 155-2- STEEL CAP 150x50x45°