DIY Network

Cargo-Trailer Kit -- Wiring and Floor From "Weekend Mechanic" episode WKM-111

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Figure A Figure B Figure C Figure D Figure E Figure F Figure G Figure H Figure I

Wiring and Floor

With the frame and tongue all assembled, the next phase of the project includes installing electrical wiring, tail-lights and installation of the plywood flooring.

Safety Alert: Always wear eye protection, and follow proper safety precaution, when working with power tools.

• To install the wiring harness onto the trailer, run a feed wire through the tongue of the trailer (figure A).
  
  
  
  
• Use the feed-wire to "fish" and pull the wiring plug and harness through the tongue section of the trailer, all the way to the front (figure B). The harness is installed in this way so that, when the trailer is tilted, the wiring harness won't bind.
  
  
  
  
• The white wire is the ground wire. File the powder coating off of a small section of the tongue and attach the ground wire to the metal frame using a ring-terminal and a self-tapping metal screw (figure C). Removing the powder coating, and attaching the terminal to bare metal will help ensure a good ground connection.
  
  
  
  
• Next, install the L-shaped brackets that will be used for mounting the brake-lights (figure D). The brackets simply bolt in place on the frame using the bolts and lock-nuts provided in the kit.
  
  
  
  
• In our kit, a license-plate bracket is installed on the driver-side light before the light is put in place. Important: Check with your state's Department of Motor Vehicles to see if you need a special license for your trailer.)
  
  
  
  
• Next, fasten the lights to the bracket (figure E), following the manufacturer's instructions for installation and wiring.
  
  
  
  
• Our kit came with small plastic clips that attach with adhesive backing to the frame (figure F) and are used to hold the wiring in place along the frame. They are installed along the inside of the frame at about every foot or so. If you don't have clips like these, you can use zip-ties to secure the wiring to the frame.
  
  
  
  
• With the wiring complete, the plywood floor (figure G) can be installed. The plywood flooring won't come with most kits. You'll need to buy it separately. Use 3/4-inch pressure-treated or marine-grade plywood.
  
  
  
  
• Measure and mark your sheet of plywood for the proper fit on the frame. Use a straight-edge to mark your lines for a nice, square fit.
  
  
  
  
• Cut the plywood to size using a circular saw (figure H).

  Tip: Cut the plywood with the "good side" (i.e., smooth surface) facing down so that splintering only occurs on the rough-finished side.
  
  
  
  

• Once the plywood is cut to size, fasten it to the metal frame using self-tapping pan-head screws (figure I).

RESOURCES :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896