Horsebox build.....our story!

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
Newbie here and hello everyone...thought it may be of interest to those who have thought about having a horsebox built to your own specifications...

Like lots of you we had been considering a horsebox for a little while..whilst our daughter was becoming more and more successful, that came with its own issues...winning local and regional events was fantastic but when she told me that she had qualified for the Nationals rather than having a huge surge of pride we were left with the oh god thoughts ...three days in a wet field in Cheshire 300 miles from home....

We took it in our stride and parked our tent and Ifor Williams trailer amongst all your pantechnicons... Three days submerged in mud, daughter sleeping on the floor of the trailer ..you know what it's like...
Well over the last few years the appeal of this is starting to wear thin... The thought of driving rusty nails into my own eyes was becoming far more attractive proposition...

So we've bitten the bullet! And this is the start of our story...

With the horror stories of VOSA victimising 7.5 tonners for being overweight we have decided to do it properly... So we went out and bought a 12 tonne Mercedes Atego HGV from a specialist lorry dealer

This was an ex office water cooler delivery lorry which was perfect for the base vehicle....it's a 4.2 litre 4 cylinder Euro 4 LEZ compliant truck.... So the first task was to get Mrs Farmer Chalk through her HGV test.... I was already in the fortunate position of possessing an HGV licence so off we went together for long romantic drives in the country with a set of L Plates with her driving everywhere...it really is not that difficult and I was incredibly impressed when she passed first time!

Next up was then to remove the old truck body....I would love to show a few photos and will do so as and when I get enough permissions from the forum moderators...
The de- bodying was done at my sisters farm with the use of a couple of telehandler forklifts...easily done cutting away the old bracketry and lifting the body straight up and driving the truck chassis away.

Unable to create a special coachbuilt body we have now contracted a local firm close to us to build the next part. So we now have the basic sleeping pod mounted above the lorry cab and this is deep underway...this week the sides of the lorry have gone up and we hope the roof will be put on it over the next few days...

The build is planned for the outer bodywork to be finished before Xmas...that will lead us to develop the interior as and when money allows through the Spring and summer of 2016...
I will try and post some relevant photos when I can. :)
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
Speaking to lots of the parents and competitors it is apparent that lots of people were in the same position as ourselves and had considered a box with living accommodation but also needed reliability....but the prices of new boxes are horrific and looking at the quality of some of them at the shows left me cold....
Hence we've bit the bullet...
Building your own however does come with its own problems and you get to understand just how involved it is.. Hence if I can post you some shots you'll see the stages involved! ;)
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
Spookily one of the most frustrating things was insuring it....the first obstacle was trying to get a company to insure a lorry but without us having a Operators Licence...this was further exerberarated when I also stated that we wanted it as a private light goods not for commercial use.....you can imagine the response when I then tried to add a provisional driver on to the policy....the computer said no!

Good old NFU Mutual stepped in and were quite happy to do the lot! But at a premium unfortunately but we were between a rock and a hard place...

First bit of advice .... Use someone else's lorry to learn in to save you a bit of cash!
 

tallyho!

Following a strict mediterranean diet...
Joined
8 July 2010
Messages
14,951
Visit site
How interesting!!! Welcome! I've been thinking about a lorry for yeeeaarrrsss but never actually bit the bullet, instead going for bigger 4x4's...

Hope to see the photos soon! I didn't know there was a limit, you learn something new everyday....
 

DirectorFury

Well-Known Member
Joined
18 February 2015
Messages
3,339
Visit site
OH (mech engineer) and I are currently finalising plans to build a one-horse (with proper living) 3.5T box so I'm really interested to see how your build goes :).
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
Still going in the vain hope of being able to post pictures which are far more exciting than my diatribe..... The build has been a long time coming and we just wanted the freedom to load it with as much stuff as we needed for the horses without worrying about weight.... The other nice thing is not laying in mud all night long!
 

Clannad48

Well-Known Member
Joined
28 February 2010
Messages
1,840
Location
Bedfordshire
Visit site
One of our daughter's friends dad builds horseboxes for a living, I used to love watching the progression from bare basics to lovingly prepared horsebox with the various extras that people wanted. I look forward with interest to your picture story of the build, I think a lot of people are extremely jealous, me included :) :)
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
I'm trying but I'm losing the will to live....still no permissions! How many do I need?
Although I'm looking forward to the day when I'm just backed!!
 

EquiEquestrian556

Well-Known Member
Joined
28 October 2013
Messages
1,581
Visit site
I need activating apparently...... What's new there according to swmbo.... See I'm even bullied here as a newbie.....:D

Oh, you may need to clarify your email address or the likes, I believe I had a similar issue when I changed my email address, and couldn't post pics until I'd pressed some link in an email. Have you had a look through your emails, to see if H&H have sent you anything?
 
Last edited:

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
attachment.php
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
I'm a bloke, can someone tell me in simple terms whether it is possible to embed an image as part of the topic or do people have to visit my gallery.... I'm afraid this forum is not user friendly!
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
image_zpsljozc5h8.jpeg
[/URL][/IMG]

Slowly getting there and please bear with me as I am a bloke....

Hopefully the first image shows the truck as we bought it. An ex Eden Springs delivery truck with low mileage and an excellent service history... It is more importantly a Euro 4 emissions truck which means it has low emissions and is currently LEZ compliant...
 
Last edited:

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
image_zpswxkmlg6a.jpeg
[/URL][/IMG]


So once we had got Mrs Farmer through her HGV the truck was then taken to have its clothes removed.... Off with the old body...


image_zpsqvcqfwmb.jpeg
[/URL][/IMG]


image_zps7ydqbndn.jpeg
[/URL][/IMG]

To reveal her in her naked best.....

image_zps1hnnafwt.jpeg
[/URL][/IMG]


image_zpswpvgn98h.jpeg
[/URL][/IMG]
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
Actually we had three! Bought in a few favours that day I tell you!

Next she was taken to the Coachbuilders....After a lot of deliberation we chose Courcheval Horseboxes near Sevenoaks in Kent.
Great chaps and I can't praise them enough...we have sat down and discussed every aspect of the build and their experience has been invaluable...
So next thing to be done was the chassis was altered at the rear end ready for the tail lift mounting..

Then the sleeper pod was grafted to the cab...

image_zpsiuyjiaov.jpeg
[/URL][/IMG]

Then the rear of the cab was cut through ready for the tilt cab walk through to be enabled...
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
Over the next couple of weeks the truck has transformed so quickly...Courcheval were very careful to get the basis of the chassis right....everything has been measured and remeasured to ensure everything sits right and the weight distribution was set up properly...

image_zpsghahcnom.jpeg
[/URL][/IMG]

Next was the metal frame work at the front of the body was welded together and the metal superstructure separating the horse area from the living area was put in place...even the height of the doorway was purposely measured to cater for my size (tall)

Then went on the side pods and underbelly lockers...

image_zpsniqe2sxl.jpeg
[/URL][/IMG]


Now the floors and side panels were fitted....

image_zpsvrsqcv9v.jpeg
[/URL][/IMG]
 

Farmer Chalk

Well-Known Member
Joined
27 October 2015
Messages
399
Visit site
image_zpslvrwlsdd.jpeg
[/URL][/IMG]

So roof should go on next to tie the body work altogether and the internal walls put up to strengthen the whole truck.

This should hopefully be followed by the windows being cut out and then bonded in place... I actually can't believe how much fabrication takes place...all of the air tanks, the battery trays and generator trays have to be relocated on the chassis in order that the steps fit where they do...

I will pop in every few days to show the transformation over the next month!
 
Top