Odyssey 4x4 Posted April 15, 2014 Share Posted April 15, 2014 I am about to be living in my Toyota full time while traveling across the country until further notice. I am bringing along with me my motorcycle for exploring towns and off-road areas and camping that the Toyota is not capable of reaching. My bike is a 2008 Yamaha WR250X weighing in right at 300 pounds. My motorcycle hitch hauler weighs in at about another 90 pounds. I hooked the hitch hauler in, loaded the motorcycle, and gave it a weight test with ~600 pounds to see how the Toyota would react. The suspension barely squatted and the airbags are at 65 pounds (max air pressure is 100 psi). With the weight test I saw that the hitch began to bend downward, uh oh! So the next step was to figure out what to do to reinforce the frame and hitch. Taking a look at the hitch you can see only small portions of the hitch were welded together and this weight started to split those welds. So upon taking a look at the truck we worked on figuring out what to do. It appears the frame extensions for the camper weld right onto the existing frame from the truck. This would work perfect. We would strengthen the entire rear of the truck by sliding heavy duty rails into the existing frame and bolting those to the trucks original frame to add all the extra strength the truck would need in the back. We would then build a new trailer hitch onto the heavy duty frame rails we added. We start with the stock rear end. Drill out the rivets and remove the bumper cover. We then cut into the rear bumper to give access to the frame extensions. Here you can see the frame rails from the extension and the thickness of the metal used. This rail goes all the way to the actual frame of the truck and welds onto it with a few spots. So the plan is to slide a heavy duty rail into the frame extension , all the way in and into the existing frame of the truck. We used a bar from a local metal shop ($50 for 11 feet). The bar is a 1.5" x 2.5" x .250" wall thickness. The bar fit PERFECTLY into the frame extension and into the frame. We were able to get this bar easily over a foot into the truck frame. This will give the truck a massive increase in support all the way to the rear of the camper. We drove it in as far as it was able to go, it took a sledge hammer to drive it all the way to where we wanted it. We then evened it out with the rear bumper. Notice the metal thickness difference from the old frame extension to the bar we are now using for support. We then repeated the process on the other side. Then we ran out of metal and time! Tomorrow we will be adding a cross support bar between the two new rails, and then welding the trailer hitch onto that structure. After that we will jack the new rear frame up to take the weight load of the truck, and then put heavy duty bolts through the frame extension into the trucks existing frame. This will put the load of the rear of the truck onto the new frame rails making it plenty strong and easily able to support the motorcycle. The hitch will also be over 5" taller than the old hitch to ensure that going up a hill will not drag the motorcycle hauler. To be continued... Quote Link to comment Share on other sites More sharing options...
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