Shenandoah the Toy Hauler

[Ghaniba]

Now, this ramp needs some structure!

Structure she got, at the cost of weight. I spent a lot of hours considering all the different ways to do the decking... HDPE, plywood, oak, scrap it all and rebuild aluminum... Every option had it's benefits, but in the end, steel is easy to work with, strong as hell and the only real big downside was weight. So, diamondplate it was.


And what do you know, a milestone was attained! The Honda SxS fits!

[Ghaniba]

With this new exciting achievement attained, we quickly threw together some layout ideas with painters tape. That was a very fun, enthusiastic hour. While all that fun was had, is was time to get serious again...

[Ghaniba]

We did the rear sheet metal for the surrounds of the ramp door. Bramber really owns this whole post. I'm blown away by his skill and experience here. They came out so awesome.

[Ghaniba]

Back to work! Added 11.5" home made angle iron to support the new skin for the sides of the bus. That was a lot of little cuts!

[Ghaniba]

Cut off all of the window rain guards. I can't believe how much that move helped it un-bus the bus!

Pro tip: 4.5" angle grinder from INSIDE, then, from outside cut the 5" or so between the windows. This really have a straight cut along the whole bus.





Next thing you know, we've got sides!

[Sleddgracer]

Originally Posted by Ghaniba

Cut off all of the window rain guards. I can't believe how much that move helped it un-bus the bus!

Pro tip: 4.5" angle grinder from INSIDE, then, from outside cut the 5" or so between the windows. This really have a straight cut along the whole bus.
Attachment 34736




Next thing you know, we've got sides!
Attachment 34737

I like your ramp design - I plan on building one similar - I've looked at several ramp ideas and hadn't found one that matched what I had in mind - this one conforms to what I have in mind and gives some details of how to achieve what I want - a couple of questions - is the winch a permanent fixture and can it be operated from both inside and outside of the bus with the ramp in the up position? - the winch gives the KISS treatment to the conglomeration of garage door springs, coils, and hydraulics that I had been considering - why did you choose a slide in extension rather than a folding one? - are you not concerned that rust will jam the slide mechanism at some time in the future? - nice job

[Ghaniba]

Originally Posted by Sleddgracer

-is the winch a permanent fixture and can it be operated from both inside and outside of the bus with the ramp in the up position?

- the winch gives the KISS treatment to the conglomeration of garage door springs, coils, and hydraulics that I had been considering - why did you choose a slide in extension rather than a folding one? - are you not concerned that rust will jam the slide mechanism at some time in the future?

I did have many iterations of this gate. Easily 30hrs of contemplation, planning, bouncing ideas off 3 different friends - Things like - "Find why this won't work" with a napkin sketch. These bus pics were just part of it:

Attachment 33100 Attachment 33101


On your questions -- I'm currently using a 2500lb winch, that is controlled by a remote, from Harbor Freight, that normally sells for $50 w/ a coupon. Super cheap, loud, slow, but fairly reliable AND EASILY replaceable as HF is located all over the country, generally speaking.


As for the slide out binding - Yes, it's certainly a concern, however I have a few thoughts:

1. My bus will mainly live under cover, right where I'm building it.
2. The ramp itself will be covered by an overhang of about 6-8" from the rear of the bus, so direct rain will not be filling them.
3. I can remove the secondary ramp and grease them, which I plan to do once I'm done welding everything.

I opted to not do the folding ramp because I want to be able to lower it, by remote, and use a second activation to kick out the extension, without having to be in, or on the bus. I believe the secondary ramp kick out will be done with a linear actuator. Mind you I will -not- need the secondary ramp MOST of the time, so in the event of this actuator failing, I could pull two cotter pins and slide it manually.


Happy to help answer any other questions!


Dave aka Ghan

[Sleddgracer]

Originally Posted by Ghaniba

I did have many iterations of this gate. Easily 30hrs of contemplation, planning, bouncing ideas off 3 different friends - Things like - "Find why this won't work" with a napkin sketch. These bus pics were just part of it:

Attachment 33100 Attachment 33101


On your questions -- I'm currently using a 2500lb winch, that is controlled by a remote, from Harbor Freight, that normally sells for $50 w/ a coupon. Super cheap, loud, slow, but fairly reliable AND EASILY replaceable as HF is located all over the country, generally speaking.


As for the slide out binding - Yes, it's certainly a concern, however I have a few thoughts:

1. My bus will mainly live under cover, right where I'm building it.
2. The ramp itself will be covered by an overhang of about 6-8" from the rear of the bus, so direct rain will not be filling them.
3. I can remove the secondary ramp and grease them, which I plan to do once I'm done welding everything.

I opted to not do the folding ramp because I want to be able to lower it, by remote, and use a second activation to kick out the extension, without having to be in, or on the bus. I believe the secondary ramp kick out will be done with a linear actuator. Mind you I will -not- need the secondary ramp MOST of the time, so in the event of this actuator failing, I could pull two cotter pins and slide it manually.


Happy to help answer any other questions!


Dave aka Ghan

thanks - I like your idea of de-busing too

[eeper38]

enjoy the build so far! im looking to make hauler for my jeep tj. do you have anymore updates?