Lightweight DIY Overland Trailer for my Volkswagen Beetle! Part 1 - Design and Metal Fab

Today's video we are going over the plan for the lightweight camping trailer build.
We are using a coleman versa trailer as the base, adding 2ft metal frame to extend the sides up taller.
We are keeping this build as light weight as possible yet packing it with as many features as we can.
I'm tired of tent camping on the ground at car shows, outdoor events, etc and always having my air mattress deflate in the middle of the night. Not to mention, it always seems to rain.
This lightweight trailer build will be towed by my 1960 VW Beetle that is a cross between a volksrod and a baja, named the Sickxty.
Thank you for watching.
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Other Channels to follow:
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Roy Works / @royworks28
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Haptic Garage / @hapticgarage 5150MXVW / swadmx
Emmitt Racing / @emmettracing
Mustie1 / mustie1
Marcijunebug / marcijunebug
Milage Unknown / @mileageunknown8910
VW Darrin / vwdarrin
EzGz / theezgz
DuckmanCycles and VW garage / duckmancycles
VW Nut 1967 / @vwnut1967 VvTheDuck vV / @vvtheduckvv
Backyard Kombi / @backyardkombi5466
Old Volks TV / @oldvolkstv
69 Baja Outdoors / @69bajaoutdoors
Wicked Werks / @wickedwerks845
V8N8T / @v8n8t
Dempop Garage / @demopgarage
Fixn Bugs N Stuff / @fixinbugsnstuff
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[@samatkinson1680]

Special welding helmet. I have watched your videos for a long while now but haven’t been the type to comment. I did want to say thank you as you have been very helpful with my own build. It’s good to know that everything doesn’t have to be perfect and the only person I have to please is me. Keep up the great work.

[@VWJawbreaker]

Thank you for being a long time watcher and I appreciate you taking the time to comment. You’d be surprised how much a comment helps a KZbinr with the algorithm plus I enjoy commenting back and forth. Appreciate you being here and happy New Year’s!

[@tophatvideosinc.5858]

Hell yeah dude. Its easy to get stuck looking at a project when you notice a weld is a little bubbly or something is off level by a degree. My coping mechanism is to step backwards until it looks good, mark down the distance for later, and make sure i dont let ANYONE get closer than that!

[@feltonbernard9618]

Great job, "Special Welding Helmet".

[@VWJawbreaker]

Appreciate you being here and Happy New Year!

[@johnfisher7716]

Special Welding Helmet...really nice addition to the Sickxty.

[@VWJawbreaker]

If budget allows, it’ll look great behind the Sickxty. I appreciate you sticking around. Happy New Year!

[@AshleyAcademy]

@ 17:44 - Came for the jibber, left with the jabber - Another satisfied viewer

[@VWJawbreaker]

Glad you enjoyed it and I appreciate you being here! 🤙

[@briancole7935]

Special welding helmets make the work soooo much fun! Looks like it's gonna be a great camper. Anxiously waiting to see what you create.

[@VWJawbreaker]

Thanks, I’m excited to be staring on this project after dreaming of it for a few years now. Appreciate you being here and Happy New Year!

[@goldentrunnell7450]

I've watched a lot of your older videos but the special welding helmet got me hooked again! This trailer build is such a cool idea. Gives me ideas for one to pull behind my 63 Baja.

[@VWJawbreaker]

Glad you’re sticking with us! I appreciate you being here and Happy New Year!

[@robertosantinni9656]

Special welding helmet. Can’t wait for part Deux!😉

[@VWJawbreaker]

Appreciate you being here! Next video will be out this Wednesday. Happy New Year!

[@backyardkombi5466]

Nice project. The skeleton you have created for this looks super strong and stable.

[@VWJawbreaker]

Thank you Greg and happy new years!

[@rustysrcgarage6935]

Special welding helmet! This is rad! Giving me ideas!

[@VWJawbreaker]

Good, go with it and build something cool!

[@vayabroder729]

That frame looks very well engineered and plenty strong. Great project. Special welding helmet 😉

[@VWJawbreaker]

It should definitely be strong enough for what I’m doing. If anything, it’s over engineering 😂 Appreciate ya man!

[@user-dt7nv5py6k]

Special Welding Helmet. I enjoy your channel.

[@VWJawbreaker]

I appreciate you being here and Happy New Year!

[@yewboup1]

This is going to be one tasty rig and special welding helmet.

[@VWJawbreaker]

It should be pretty cool once it’s all together. Happy New Year!

[@TrixedOut]

Special Welding Helmet! Great video! Can't wait to see the end product!

[@VWJawbreaker]

Appreciate you sticking around! It’ll come together pretty quick over a few videos. Happy New Year!

[@usaeatt2]

Special welding helmet. Happy to see you in 2024!!! Looking forward to more crack-a-lackin this year!

[@VWJawbreaker]

Thanks, I appreciate you sticking around! Hope we all have a great year 🤙

[@user-ym8lt3js7l]

Love the concept and great execution so far! But what you really need is a SPECIAL WELDING HELMET! 😀👍👍

[@VWJawbreaker]

I appreciate that! It’ll come together pretty quick! Thanks as always for being here and Happy New Year!

[@bigboardfun]

Special welding equipment. Nice work.

[@VWJawbreaker]

Thanks for sticking around and Happy New Year!

[@annies_vw]

love that special welding helmet! and this is going to be so awesome! so far so good. looking robust and sturdy!

[@VWJawbreaker]

It should be plenty strong although I end up adding more bracing off camera 😂 Go fidget, overkill should be my middle name 🤷‍♂️

[@gerhartpeter]

Such a great idea. May need to do this for my Baja! Loved the special welding helmet.

[@VWJawbreaker]

Should still be lightweight enough when done, most should be able to pull it. Worse case there’s ways to keep the weight down more.

[@douglasbarnhart3324]

Thanks Gary for the video!! Special welding helmet..

[@VWJawbreaker]

Always appreciate you being here my friend. Happy New Year!

[@toad7487]

Cool build, oh, and that special welding helmet, wow!

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@bennyt.christensen3970]

Nice work you did with that special welding helmet on 🚙⛺

[@VWJawbreaker]

Appreciate you being here and happy New Year’s!

[@ineverhadthemoney7857]

I like your work saving a Volkswagen Beetle// as they where made //for the people // not off road , so wish you well //good bye .

[@VWJawbreaker]

They were made for the people and the people modified them in many ways. Can’t please them all, happy New Year!

[@joechapin4897]

Special welding helmet. Love your videos

[@VWJawbreaker]

Appreciate you being here and happy New Year’s!

[@zimms-world]

Special welding helmet. That’s a cool idea.

[@VWJawbreaker]

Thanks buddy! Should solve our camping issues.

[@kyridgejumper]

Special welding helmet. Great idea and good use of what you already had My kind of build

[@VWJawbreaker]

That’s how I prefer to do most projects, plus it helps keep the costs down if you can reuse things. I appreciate ya being here! Happy New Year!

[@MAGAisacult]

Love it!!!! Fun project I have considered myself many times.

[@VWJawbreaker]

Thanks! Been thinking of this for several years, excited to finally be moving forward! Happy New Year!

[@priscellaconrad5693]

So excited to see this! I bought a versa trailer for $100 with the same idea ❤

[@VWJawbreaker]

That’s awesome! There’s plenty of videos in the playlist showing how and what I did. Use that to help inspire you to build yours into your dream!

[@alanross2305]

Awesome creation. Can’t wait to see how it turns out. Love the Special Welding Helmet you wear!

[@VWJawbreaker]

Thanks! It’ll come together pretty fast and won’t be dragged out. Happy New Year!

[@DesertRatFabrication]

Special welding helmet, hey Gary sweet video, sweet camper trailer, I’ll be checking the next one out soon, have a good week buddy😀😀

[@VWJawbreaker]

I appreciate ya sir! Trust me, it’s gonna turn out pretty cool!! Have a fantastic week and hope you’re staying warm!

[@SpiralDesignWorks]

Looking good.

[@VWJawbreaker]

Thank you 🤙

[@maniestrijdom7271]

I always dream of a teardrop trailer but am following this build! Got 64 bug as a tow rig!

[@VWJawbreaker]

I’m too tall for a tear drop trailer or I would have loved to go that route. Happy New Year!

[@TheEZGZ]

special welding helmet. I'm concerned about aerodynamics. Flat surfaces are nice when camping for long periods but going down the road is tuff. Good to take time and smell the roses when traveling. Love to have you visit me in Colorado

[@VWJawbreaker]

I do agree, the original plan was to have the front have a V shape to it but I got busy building and forgot 🙄 figures lol Considering it’s not too tall, it shouldn’t provide too much drag when being towed. Guess we’ll see lol Trust me, if I can ever make it out your way, you’d be the reason I go to Colorado!

[@davidryan573]

Makes total sense, making it that size and height, keep it easy to tow, I hate being stressed out over a trailer, I hope you get your special welding helmet 😂, thanks Gary Happy New Year 🎉

[@VWJawbreaker]

Absolutely, should be easy to tow and not have too much wind resistance. Appreciate you being here and happy New Year’s!

[@aj1696]

Special welding helmet . looks cool ...

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@dillyd3488]

Looks good! Special welding helmet

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@eduardorodriguez3262]

Special welding helmet... BGood👍🇩🇪

[@VWJawbreaker]

Appreciate ya! Happy New Year!

[@eduardorodriguez3262]

@@VWJawbreaker Happy New Years to you as well👍🇩🇪

[@douglasberry7004]

Special welding helmet🎉

[@VWJawbreaker]

Appreciate you being here! Happy New Year!

[@mikemoreno2444]

cool idea

[@VWJawbreaker]

Thank you and Happy New Year!

[@eddiestephens5213]

Special welding helmet. I plan to do something similar for my Thing so very timely. Thanks!!

[@VWJawbreaker]

Use any, all or none of my ideas, it won’t bother me! We all inspire each other and that’s what counts. Appreciate you being here and happy New Year’s!

[@thebinderbuilder]

Bro! I was just thinking of doing this myself. Like yours, my Baja won't have a roof rack and so my storage is extremely limited. Can't wait to see this thing come together, especially the utility items... Power, food storage options, and cooking implements!

[@VWJawbreaker]

I’ve been dreaming of this for several years now, so excited to finally get started! Of course this revision isn’t close to the original idea but it’ll be better in many other ways. Stay tuned, loads more to come!

[@thebinderbuilder]

@@VWJawbreaker #StayingTuned

[@deanrobinson3717]

Excellent welding Gary, see that the grinder kissed your hand too, that’s usually my trick, and by the way Special welding helmet , have a great birthday and even better year

[@VWJawbreaker]

Exactly why I usually wear gloves…. I don’t like those kind of kisses 😂 Always appreciate you good sir. Thank you much and happy new year!

[@V8N8T]

That's awesome Gary and will be a great addition! Oh yeah Special welding helmet! Happy new year

[@VWJawbreaker]

It’ll be awesome once it’s fully done. Appreciate you being here as always and happy New Year’s to you all!

[@boxerboys2752]

Nice work..! 👍

[@VWJawbreaker]

Thanks! Happy New Year!

[@uksniper1]

Special welding helmet 😂,, nice work mate, gave me a few ideas too pal thanks👍😉🍺..all the best Wayne👍

[@VWJawbreaker]

Awesome, glad I’m helping inspire some ideas! Appreciate you being here and Happy New Year!

[@easternWashington.]

When you have special welding to be done, grab the special welding helmet

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@ChipsAndSparksGarage]

Nice project, Gary! It’s coming together pretty quick. Must be the special welding helmet! 👍

[@VWJawbreaker]

Thank you sir! Happy New Year and hope all is well.

[@stewartegerton436]

Special welding helmet 😊

[@VWJawbreaker]

Appreciate you being here.

[@davidgiesfeldt6650]

Look into the 13” radial tire up grade. Better tracking. SPECIAL WELDING HELMET!

[@VWJawbreaker]

I’ll do that, thanks 🤙

[@lawrenwimberly7311]

special welding helmet... Happy new year

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@hummv8]

Doing good!! special welding helmet. Idea? Maybe angle the front instead of flat for more inside space and less wind resistance

[@VWJawbreaker]

I did think of angling the front and even had it in the original plans…. Then I got busy and forgot 😂 Appreciate you being here and happy New Year’s!

[@dagen_1]

Special welding helmet. Happy new year!

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@69bajaoutdoors]

Happy New Year brother!!! Looking good! Miscalculations happen. Happens to me more than I would like to admit but we learn and fix our mistakes. You and I think a lot alike and I will be building my camper as soon as the baja is finished! Tight work!

[@VWJawbreaker]

Thanks man! I’m excited to be working on this finally. Appreciate you being here and happy New Year’s!

[@masbeetleboy9169]

Happy New year Gary. I like this new project and your special welding helmet. So far, everything looks interesting.

[@VWJawbreaker]

Appreciate it! Happy New Year!

[@VWRICH23]

Special welding helmet.. happy new year 🎉

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@justinanderson1727]

Shpeshel welding heel mat

[@VWJawbreaker]

Appreciate you being here 🤙

[@royworks28]

Great job, special welding helmet. Happy New Year

[@VWJawbreaker]

Thank you sir. Happy New Year to you all!

[@HubertusSchaper]

Hi Garry, Great update on the 1e day of the new year 2024, first of all, wish you and your dear ones a great New Year 2024 🇺🇸⭐🍀🌟 may all your wishes and those from the family be fulfilled and above all healthiness and prosperity🍀, stay safe take care and be good.Greetings from the Old 🇳🇱Dutch 🇳🇴Norwegian Hubertus.🙏🏻cheers🇳🇴☮🇳🇱🍷🇺🇸

[@VWJawbreaker]

Hi Hubertus! Wishing you and yours a wonderful and safe New Year!

[@2GuysandaBug]

Happy New Year. Love this project and look forward to all the glamping gear you add. Special welding helmet.

[@VWJawbreaker]

Happy New Year! It’ll be outfitted pretty decently and will be a pretty quick build.

[@user-jx8cs6hk2g]

Happy New Year, Stony from Canada Ontario awesome BAJA

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@vdub6873]

Sooo awsome now u can come camp pensacola with us.....diesel heater going in too?? Special welding helmet

[@VWJawbreaker]

That’s the plan my man, I’ll now have somewhere to stay and I can travel more! Happy New Year!

[@raymondwilkerson5069]

I love this trailer build. As I was watching I was thinking that maybe you would like a slide out floor to help with stowing and removal but also act as a tailgate for camping and hanging out? Just an idea.

[@VWJawbreaker]

Honestly the slide out is down the road but not in the near future. I’ll only be doing a section of the floor and you’ll see why in the next few weeks. Happy New Year!

[@dm8399]

Happy New Year.....special welding helmet!

[@VWJawbreaker]

Happy New Year and thanks for being here!

[@STREETSTANG07]

Happy New Year! Looking forward to your videos in 2024

[@VWJawbreaker]

Happy new year!

[@raymondwilkerson5069]

Special Welding Helmet

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@oldvolksbus]

special welding helmet! great video. as you know, i have a bus! would love your setup. @oldvolksbus!

[@VWJawbreaker]

Thanks man! Yeah, a bus just doesn’t fit the bill for us plus I could build this multiple times vs a bus. Plus this will allow me to setup and still leave in the bug 😎 Happy New Year!

[@ricksalmon4916]

Special Welding Helmet.

[@VWJawbreaker]

Appreciate you being here! Happy New Year!

[@battyboomfatty]

I recently paid decent money for what I thought was a Special Welding Helmet from R-Tec. When it's arrived it feels a bit chinese. Although it works brilliantly.

[@VWJawbreaker]

Haha, love what you did there! Appreciate you being here 🤙

[@75vw]

Special welding helmet!

[@VWJawbreaker]

Appreciate you being here and Happy New Year!

[@jeffcoleman5160]

Great video Gary.🤔so my last names Coleman that means the trailer was mine.Happy New Year sir.

[@VWJawbreaker]

Sorry I stole your trailer 😂 Happy New Year!

[@darrellowensjr7030]

Special welding helmet

[@VWJawbreaker]

Thanks for playing along 🤙

[@cjjones1556]

Special helding welment. This project has been on my mind. Get out of my head.

[@VWJawbreaker]

Haha!! 😂 I’ve been thinking about this being behind the Sickxty for about 2 years now 😎 Appreciate ya being here man and happy New Year 🤙

[@BrewDub73]

Lookin good, brother! Excited to see the next video. Do you wear special welding helmet in that one too? 😂😎

[@VWJawbreaker]

Thanks brother! I always wear special helmets 😂

[@nealchristensen1793]

Good to see you back jibber jabber or not look's like fun ! Where'did you get that Special Welding Helmet ?

[@VWJawbreaker]

I appreciate that! I’m glad this is all coming together, been dreaming of this for a long time now. Happy New Year!

[@user-eg3yv3xr7s]

special welding helmet

[@VWJawbreaker]

Appreciate ya being here 🤙

[@basecamp3098]

Special welding helmet .

[@VWJawbreaker]

Appreciate you being here and happy New Year’s!

[@BiGJohnnyB]

Special Welding Helmet....

[@VWJawbreaker]

Appreciate you being here and happy New Year’s!

[@Paulman50]

Special helmet welding, 😂

[@VWJawbreaker]

Appreciate you being here as always sir and happy New Year!

[@user-jx8cs6hk2g]

hi should have used a VW half Shell for Trailer

[@VWJawbreaker]

Do you have one?

[@allisonroe-dp6bs]

Special welding helmet 😂

[@VWJawbreaker]

Appreciate you being here. Happy New Year.

[@kevinhamling1963]

G'day, Mr Gary, This looks awesome. I've been thinking about something similar for Betsie to pull. Q. How many bedrooms does the trailer top tent have. 🤔 So thanks for sharing man ✌️ Peace from Melbourne Australia. Special welding helmet.

[@VWJawbreaker]

Hey Kevin!! Happy New Year to you all! Only one room in the tent but it should be big enough for the 2 of us. I’ve been dreaming of this build for the last few years, excited to finally getting started.

[@kevinhamling1963]

@VWJawbreaker When it's all done your gunna have a nice set-up. And you see dreams do come true. 🤗

[@anthonynkusable]

love the beetle, what kind of wheels, tires on it?

[@VWJawbreaker]

There’s a complete playlist on that build. 30x9.5’s on 15x8 rims all the way around.

[@vintage76vipergreenBeetle]

Welding helmet.

[@VWJawbreaker]

Appreciate ya man. Happy New Year

[@tophatvideosinc.5858]

found your channel by image searching my trailer which i got off of cragslist for 60 buck. exact same as far as i can see, and exactly what i want to do with it. fella wanted 600 but his wife though he said 60 and she chewed him a new ass until he caved.

[@VWJawbreaker]

Awesome and welcome! That’s a killer deal on the trailer, sounds like the right place at the right time. Hope something in the videos will help inspire your build as these trailers are pretty versatile and can handle some decent weight.

[@tophatvideosinc.5858]

@@VWJawbreaker yeah my plan is to get some 1/8 aluminum sheet from my local Coremark and make a new cover in place of the fiberglass one. The original was propped open on gas struts for probably a decade and it decided to take on a new shape. With the aluminum cover, ill shore it with an angle stock frame so it can take weight. Then mount the old crossbars from my now retired 1998 rav4. Which i can hopefully interchangeably switch between a basket on top or a tent, depending on if i dont have roof space on my vehicle. Of course, thats just my napkin sketches. Finding your videos and watching them right now will help me solidify a plan that makes more sense. So far im loving yours.

[@tophatvideosinc.5858]

@@VWJawbreaker im severely limited in my capacity to weld too. Welder is on its last legs and i can only do a couple dozen tacks before the wires start to smoke. So ill be relying on riveting the aluminum panels on for strength probably. But the more daytime i lve got, the more tacks i can lay, even if it takes 12 hours.

[@VWJawbreaker]

@@tophatvideosinc.5858 sounds like a solid plan! Google “space trailer” as they are basically what you’re describing, those may also give you some ideas. That’s one of the many good things about KZbin, we can help inspire each other to get our projects started and done. There’s so many different ways to do things as long as you’re happy with the finished product and it works for your intended purpose, that’s all that matters.

[@tophatvideosinc.5858]

@@VWJawbreaker anyway, glad i found your channel. You seem to be pretty experienced with fabrication. My experience is on the opposite end, i professionally finish metal fabrications, billets and castings. So ill make up for my crappy fab skills by making it look pretty 👍

[@robbyd.4037]

Special Welding Helmet

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@user-hq6gx3jh2x]

Special welding helmet

[@VWJawbreaker]

Thanks for being here and Happy New Year.

[@DennisL968]

special welding helmet

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@georgeezzell4474]

Special welding helmet.

[@VWJawbreaker]

Appreciate you being here. Happy New Year.

[@abelwilson9911]

Special Welding Helmet

[@VWJawbreaker]

Appreciate you sticking around! Happy New Year!

[@richs8404]

Special Welding Helmet

[@VWJawbreaker]

Appreciate you being here and happy New Year’s!

[@1fastbuggy502]

Special Welding Helmet

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!

[@dustinbrown3815]

Special welding helmet

[@VWJawbreaker]

Appreciate you being here and Happy New Year!

[@user-gj5hc7ko2k]

Special welding helmet

[@VWJawbreaker]

Thanks for being here and happy New Year

[@maxsvwgarage9861]

Special welding helmet

[@VWJawbreaker]

Appreciate you being here. Happy New Year.

[@craigVW66-73]

Special welding helmet

[@VWJawbreaker]

Appreciate you sticking around and happy New Year!

[@frankfullone5283]

Special welding helmet

[@VWJawbreaker]

Appreciate you being here buddy and Happy New Year!

[@prkid424]

Special welding helmet.

[@VWJawbreaker]

Appreciate you being here. Happy New Year.

[@carlosmartoral6268]

Special welding helmet.

[@VWJawbreaker]

Appreciate you being here and Happy New Year!

[@superveganwhat]

Special welding helmet

[@VWJawbreaker]

I appreciate you sticking around. Happy New Year!