01Donor96.JPG
698 hits | 57.71 KB | Posted: 10/6/11
This is the axle donor. Apparently, everything after '97 is coil-sprung/IRS.

01Donor97.JPG
547 hits | 51.55 KB | Posted: 10/6/11
This one had the same axle, but others of the same year range have a smaller lug pattern, so pay clo...

02Donor.JPG
668 hits | 85.74 KB | Posted: 10/6/11
I chose this donor because the brackets are designed to mount to a nearly-flat surface. Only the re...

05Axle.JPG
737 hits | 94.08 KB | Posted: 10/6/11
This cost less than $100, which is less than a cheap trailer axle alone. This one includes brakes, ...

06FrontW.JPG
541 hits | 84.32 KB | Posted: 10/6/11
Just measurements taken during the planning stage.

07RearW.JPG
575 hits | 77.66 KB | Posted: 10/6/11
Just measurements taken during the planning stage.

08Drop.JPG
502 hits | 96.44 KB | Posted: 10/6/11
I chose this axle for its deep drop. The lack of ground clearance doesn't matter since the cross tu...

10Lowest.JPG
634 hits | 73.65 KB | Posted: 10/6/11
The shocks hang slightly lower than the drums, which is perfect - they're expendable, so they'll pro...

11BoltCircle.JPG
527 hits | 85.75 KB | Posted: 10/6/11
This axle has the common 5-on-4.5" lug circle, but the larger 2.8" hub stickout, so rims s...

12WMS.JPG
527 hits | 82.7 KB | Posted: 10/6/11
Just measurements taken during the planning stage.

13LengthF.JPG
607 hits | 88.73 KB | Posted: 10/6/11
Just measurements taken during the planning stage.

14Bolt.JPG
1538 hits | 135.64 KB | Posted: 10/6/11
While checking the fit without the brackets, I found the front bolts seized in their bushings. This...

15BoltPress.JPG
1237 hits | 118.2 KB | Posted: 10/6/11
While checking the fit without the brackets, I found the front bolts seized in the bushings. This b...

16BoltPressed.JPG
1121 hits | 101.62 KB | Posted: 10/6/11
Small wonder they were seized - I doubt any amount of hammering would have removed them. Certainly ...

20FlangeS.JPG
646 hits | 87.97 KB | Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.

21FlangeR.JPG
599 hits | 71.64 KB | Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.

22WebE.JPG
612 hits | 82.28 KB | Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.

23WebF.JPG
618 hits | 77.16 KB | Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.

24WebR.JPG
587 hits | 65.38 KB | Posted: 10/6/11
Just checking - nothing is drilled or bolted yet.

31Bolt.JPG
591 hits | 99.94 KB | Posted: 10/6/11
Eventually, I settled on this orientation: the front brackets bolted to the web of the I-beam, and t...

32Shackle.JPG
587 hits | 97.12 KB | Posted: 10/6/11
I'll probably reinforce the holes thru the flanges, but this is good enough to get it rolling.

34Corner.JPG
572 hits | 71.85 KB | Posted: 10/6/11
The gap is almost exactly 3/4", so I'll use plywood for the deck.

35Strapped.JPG
638 hits | 100.1 KB | Posted: 10/6/11
To prep it for welding, the frame is strapped together.

36Saw.JPG
557 hits | 93.33 KB | Posted: 10/6/11
A carbide-tipped rip blade works surprisingly well on Aluminum. Even thick stuff.

37Tubes.JPG
615 hits | 110.32 KB | Posted: 10/6/11
The floor joists are a snug fit.

38Tacked.JPG
603 hits | 97.43 KB | Posted: 10/12/11
I've tacked the tongue together, and it's pinned to the leaf spring brackets so the deck can tilt.

39Tongue.JPG
585 hits | 95.58 KB | Posted: 10/12/11
The tongue is long enough that the frame clears a fullsize truck bumper, and the jack is back enough...

40Cables.JPG
578 hits | 95.12 KB | Posted: 10/13/11
The single L e-brake cable has been swapped for a 2-piece R so they match. I'll cut the tubular guid...

41SpareSpace.JPG
556 hits | 100.71 KB | Posted: 10/13/11
27.5" should be just enough room between the front 2 floor joists for a hidden spare tire.

42TongueWelded.JPG
542 hits | 100.2 KB | Posted: 10/25/11
I borrowed a Lincoln wire-feed and burned the tongue together. It's certainly not professional-qual...

43CableBrkts.JPG
500 hits | 82.35 KB | Posted: 10/26/11
I finally came up with an idea for the the e-brake cable brackets that eliminates one set of tubes, ...

44CableR.JPG
522 hits | 89.48 KB | Posted: 10/26/11
The cable easily clears the tire, and will have even more room after I add the 2" wheel spacers.

45CableR.JPG
546 hits | 83.78 KB | Posted: 10/26/11
There's a tab behind the spring backet that prevents it from rotating on the single bolt.

47Tilt.JPG
520 hits | 99.62 KB | Posted: 10/26/11
The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t...

48Tilt.JPG
523 hits | 99.36 KB | Posted: 10/26/11
The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t...

49Tilt.JPG
520 hits | 95.16 KB | Posted: 10/26/11
The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t...

51Prepped.JPG
595 hits | 63.47 KB | Posted: 10/31/11
This is the first time I've actually fitted everything at once. The shock mounts will have to move ...

52ShockBlock.JPG
526 hits | 70.69 KB | Posted: 10/31/11
The slot on the other side was too high - the bolt hit the frame. So I swapped the tubes & cut the ...

53Box.JPG
512 hits | 94.9 KB | Posted: 10/31/11
The ammo can will hold straps, spare lug nuts, tire chocks (etc.), and the lug wrench stows neatly b...

54Space.JPG
531 hits | 102.85 KB | Posted: 11/3/11
2-inch spacers are just what it needed to clear the frame.

55Spacer.JPG
535 hits | 98.39 KB | Posted: 11/3/11
These spacers came from eBay. They're not listed for a '97 Caravan because the lug threads are diff...

65Struts.JPG
506 hits | 110.84 KB | Posted: 11/11/12
I finally found some junkyard lift struts that would fit & work to hold the deck tilted, and install...

66Struts.JPG
508 hits | 112.02 KB | Posted: 11/11/12
I finally found some junkyard lift struts that would fit & work, and installed them. To keep them fr...

68Struts.JPG
469 hits | 106.07 KB | Posted: 11/11/12
I finally found some junkyard lift struts that would fit & work to hold the deck tilted, and install...

69PinCable.JPG
408 hits | 78.34 KB | Posted: 6/15/13
To keep the pin from ever going missing, I cabled it to the trailer.

69SpareCables.JPG
424 hits | 92.69 KB | Posted: 6/15/13
Cables on the front of the spare tray will keep it from sagging, or the spare from sliding too far f...

70WhCvrt.JPG
445 hits | 87.58 KB | Posted: 6/15/13
These little covers should be enough to keep me legal, and they're just strong enough for me to sit ...

70WhCvru.JPG
477 hits | 95 KB | Posted: 6/15/13
These little wheel covers should be enough to keep me legal, and they're just strong enough for me t...

71Rails.JPG
578 hits | 108.44 KB | Posted: 8/1/13
The stake pockets are spaced the same, so these rails fit in any position.

The fiberglass reflectiv...