Snags and the First Problem

After fabricating the front section and sliding it over the main frame rails it was incredibly difficult to get it aligned to make sure the tongue is centered and the frame is square. I'd adjust it which was difficult due to the size and weight. Then I'd remeasure to each "axleless" axle mount and then measure to each back corner. Then measure the main box for square. This repeated for 5 days with adjustments, and I just couldn't get it to square or when it was square the tongue was misaligned and the happy medium was too far out for me to be acceptable.

In the end I think some of the front wings where they attach to the frame distorted from the welding or weren't quite square but after so many days I scrapped the entire front assembly shown in red here: {media:4}

I was quite frustrated and didn't get hardly any pictures though. I started with one piece across the front of the frame rails, squared the main frame and front rail then added one piece at a time, tack welds until it's all square. I tacked a temporary support across the frame to hold it in place and square and then cut a slot in the front for the tongue, so it'd be centered and square. That worked great!

Started with a piece across the front:

Then added the sides and kept everything square or as square as possible.

But I probably wasted 2-3 weeks of working on the trailer with the old front assembly, fabricating it and then trying to align it before scrapping it and starting over. Oh well! I didn't get any pictures when I rebuilt the front of the frame either since I was pretty annoyed at the situation.

I built some "rotisserie" stands and bought some metal pipe so I could rotate the frame for final welding. I'm not the best at out of position welding and wanted to ensure the welds are solid and the best I can do for something as critical as the frame.