Homebrew Trailer Tire Rack

Up until recently I have been carrying my extra race slicks and rain tires in the back of my truck.  Not too long ago I got a mid-rise ARE bed cap, which certainly made it easier to carry and secure all the track extras.  But it was still a pain to crawl up into the bed to get wheels out, especially since I was loading them towards the front for better weight distribution.  They were also taking up a lot of room in the Titan’s short 5.5′ bed.

Tire rack in progressI’d been wanting to get an aluminum trailer tire rack to match the aluminum open trailer.  Unfortunately there isn’t anything off the shelf that would work, it would have to be completely custom.  I’ve got a MIG welder, but no spool gun for welding aluminum.  So I decided to go the simpler (and cheaper) route and build one out of steel.

I built the rack entirely out of 1.5×1.5″ square and 1×2″ tube, both in 14 ga wall thickness.  I also wanted a better method to store the fuel jugs.  Previously I was strapping them down individually to the tool box, which was time consuming to do and not very clean.  The solution was a couple horizontal bars for the jugs to rest on, with another bar to capture them at the rear.  The front of the jugs rest against the tool box.  I welded on four small tie down rings to hook a ratchet strap into and run through the handles of the jugs.  The jugs are raised off the trailer deck to provide room for the Warn winch located below.

Fuel Jug Tie DownsAnother feature of the rack is that it is completely removable from the trailer.  The trailer came equipped with stake holders along the perimeter, used to hold 2×4″ wood.  The “feet” of the rack go down into these stake holders to provide lateral and longitudinal support.  Four J-bolts secure the rack to the trailer, which hook into the bottom of the stake holders.

To secure the wheels to the rack I went with the standard method of running a tube though the bores.  To prevent damage to the wheels finish I used a piece of gray electrical PVC conduit as the outer portion of the tube.  Inserted into the PVC pipe is a galvanized steel electrical conduit tube to provide strength.  The two pieces are permanently boded together with black polyurethane sealant.

Tire Rack Wheel LocksThe tube slides through an oversized hole cut into a piece of plate steel which is secured to the rack using M8 nutserts and stainless bolts.  I cut oblong holes into the plate to allow for adjusting the height of the tube for slightly different tire sizes.  If necessary, a completely different end plate can be made and installed for much larger or smaller wheels/tires.

I drilled a hole through the tube on both ends of the tube to allow for installing a lock.  I did it on both side in case one side is blocked by another trailer/truck in the paddock.  This way I can remove the tube from either side.

I finished off the rack with a coat of Rustoleum red primer, followed by aluminum spray paint.  I know I’ll have to go back and touch up several spots, especially where the tires rub the horizontal bar.  Ideally I would like to get the entire thing powdercoated.

In the photos you can see cardboard between the wheels, which was a temporary solution to keep the wheel faces from rubbing each other while travelling.  Since these photos were taken I have procured some corrugated plastic (same stuff used to make yard signs) to act as a cushion between the wheels.

Front of the Tire Rack Back of the Tire Rack

Moving a Bare Chassis

I had to devise a plan to move two bare chassis, one taking up room in my garage and another in front of the house.  With no running gear, it would require some method of wheeling them around.  If I had a flat driveway this would be cake, I have enough furniture dollies to just slide them around.  But things get rather complicated with a steep driveway and the need to move the car up to the side yard. I figured I’d need the truck to get the car, even in its lightweight form, up the grass and into my side lot.  That necessitated using some form of a trailer.  I ended up purchasing the cheapest Harbor Freight utility trailer I could (aren’t they all cheap, well at least cheaply made?) and modified it to suit my needs. Rather than bolting it together, which always results in making an already flimsy contraption that much more flimsy, I welded the entire thing together.  I also needed to stretch the tongue out six feet so that it would reach from under the car.  I then welded on a tongue jack to keep the whole thing level when not hooked to the truck.

Trailer Under CarWelding Trailer

The process wasn’t very elegant, but it worked.  I jacked up the car fairly high on jack stands space as widely as possible, then rolled the trailer underneath, trying to keep the majority of the weight over the tongue to prevent it from popping a wheelie.  I ran one ratchet strap around the bottom, hooked into the door hangers to help keep the car stable.  From there I simply backed the shell up into my side lot so that I can power wash the chassis and remove as much undercoating as possible.

Picking up a Caged E36 Shell…. then smashing it.

I have been, for the longest, working towards building up a BMW E36 M3 Coupe into a true race car.  You’ve seen some of the work I’ve put into the white ’95 currently gutted and resting in my garage.  It was approaching the point where it needed to go off to the cage builder.  Around the same time as I was hunting for a few last minute parts, I received a heads up from Bimmerworld’s own (and owner) James Clay that there might be a caged E36 shell available in Houston.  It was built by Bimmerworld a while back, starting life as a ’94 325i.  It was intended for NASA GTS racing, most likely the GTS-2 class.  The current owner of the car had some medical issues that would prevent him from continuing with the project, and he wanted it and every associated part gone.  This sounded like just the ticket, saving me time (possibly money too) in having a fully built cage and plenty of spares ready to go.

Removing the rear subframe of my M3 and finding several damaged areas sealed the deal, and I made the trip down to Houston with my open aluminum trailer to retrieve the car and parts.  The car was truly just a shell; no engine, transmission, rear subframe, or anything required to make it a roller.  Fortunately the owner had reinstalled the front subframe, struts, rack, and uprights, so it was sitting on its front two feet.  There was no rear subframe, so we used a furniture hand truck to help move it.  Despite not having running gear, the car still wasn’t exactly light having been slap full of spare and new parts.  We managed to get everything loaded, with some help from a come-along and numerous ratchet straps.

325i loadedWith everything loaded, I set off for home, which meant traveling through the congested heart of Houston.  I was poking along I-45, less than 30 minutes from my start point, when a brief lapse in my attention ended everything before it barely started.  I had taken my eyes off the road to check that my left side was clear in order to change to the center lane when I found myself on a collision course with a concrete barrier.  At the last fraction of a second I avoided impacting the water filled drums protecting the corner of the barrier… at least with the front of the truck that is.  The side view mirror clipped the barrier, the right bedside swiped it, then the right wheels of the trailer landed home… hard.

Trailer WreckThe axles were instantly torn from the trailer, taking about 3/4’s of the decking and frame with them.  Fortunately the car remained secured to the trailer, lucky that it was being towed backwards, as the front tires surely took some of the shock.  Even more fortunate that no one was hurt in the ensuing debris cloud that sent pieces of aluminum not only into the adjacent lanes but even over the divider into the southbound side.

It ended up damaging 9 other cars, mostly cosmetic, but several wheels were busted from running over the debris.  There were also four wheels and two tires secured to the trailer, which were all scattered across the highway.  It was a disaster to say the least, you can imagine what it did to the already dense traffic (good thing it was a Sunday and not rush hour on a workday.)

All that was left of the trailer Remains of the trailer Damage to rear of Titan Car getting loaded 325i Loaded on Rollback 2 325i Loaded on Rollback 1

So after dealing with the police and the multiple folks seeking my insurance info, I left for home empty handed.  Perhaps a saving grace was that I had two full sets of race tires and wheels in the bed of the truck, including a set of BBS’s which were all unharmed.

Now I had to figure out how to get the car back to my home, with no more trailer in my possession.  While on my way home, I received a message from Dave at DDPR, asking if I was still planning to stop by the shop.  D’oh!  That’s right, I was planning to stop by his shop in Sealy on my way home to check out the Spyder.  Obviously I was a little scatter-brained following the incident, so I hadn’t let him know I wasn’t going to make it.  I shot him a reply with an attached photo of the carnage.  Dave called almost immediately to make sure I was alright, I had just pulled into my driveway.  He then offered me use of his enclosed trailer should I need it to pick up the car, what luck.  A couple days later I took him up on the offer, driving back to Houston to pick up the remains.

After haggling with the tow yard owner, and exchange of way too much money, I was finally allowed into the back of the yard to retrieve my car and trailer.  Sidenote: If at all possible, avoid doing any business with Fiesta Towing in Houston.  One of the workers had enough compassion and common sense to help me out, despite the owner’s quibbling.  I backed the trailer in, finding the car just like this:

325i in Tow Yard

Car in the tow yard Trailer backed up

I had brought a buddy along to help with the task, this was definitely a two man job.  The trailer we brought was equipped with a winch, but it would still take a little redneck ingenuity to get everything loaded.  Thankfully I had brought tools, including a cordless sawsall and impact driver.  We decided we had to separate the car from the trailer, which required cutting the remaining frame rails from the tongue.  We then zipped out the bolts holding the tongue jack, so that we could place the trailer on furniture dollies.  The winch made short work of pulling the remains inside the enclosed trailer.

Trailer pulled inside

Now for the car.  The hand-truck that was used to load the car the first time had been badly damaged during the wreck, making it useless.  This had also crushed the spare tire well, leaving us few options for placing dollies under the rear of the car.  That’s when, with another stroke of genius, we took a scrap piece of the trailer’s aluminum and laid it across two of the dollies.  We stacked some wood planks on top of that, then used this as a beam under the bottom of the car.  Using my floor jack we lowered the entire car down onto the dollies, which were then strapped to the car.

Waiting to lower car on dollies 325i resting on dollies Damage to spare tire well Empty space waiting on car

With the car’s rear end resting on the dollies, I ran a large strap around the piece of aluminum sandwiched between the car and dollies.  Then I connected the winch’s hook to the strap, from there it was just a series of pulls and adjustments.  I wasn’t able to catch any photos, as our hands were full, but you get the idea.  With the car finally in, we strapped everything down securely, and headed back home.

Finally home and unloaded.  I think I need to change my doorbell to play the theme song from Sanford and Son.

Full House

Transmission and engine mated, off to SC

Well I got the transmission all finished up. Painted, shifter in, throw-out bearing and fork:

transmission_finished

Got the Fidanza flywheel and ACT clutch on:

clutch_installed

Then, after much sweating and cursing, got the engine and transmission mated:

engine_tranny_hanging

Built a simple wooden stand for the engine/trans to rest on:

engine_wooden_stand
Don’t worry, those straps are merely holding the stand to the engine. The whole piece was strapped down tight. Kudos to Nissan and their Utilitrack!

Then the car was loaded up. This was quite an ordeal, as the sides of the trailer only gave a couple inches of clearance. This meant I had to drive it up, pop the top, get out, close the top, use some safety wire to roll the windows up, use another piece of safety wire to pop the hood, then disconnect the battery (keys couldn’t be reached.)
car_loaded

The Titan-Spyder-Titan sandwich:
convoy