Horsebox build.....our story!

Can't believe that you are actually going to let horse and family use that. Can it tow - I'd put them in a trailer behind it...
Seriously nice bit of kit. Thank you for sharing your journey.
 
AdorableAlice said:
I have posted the squitty carthorse to you, has he arrived yet. That lorry needs a proper christening.
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Thanks Alice....not so adorable....yes he has arrived...
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:D:D:D
 
Farmer Chalk said:
Thanks Alice....not so adorable....yes he has arrived...
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:D:D:D
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Where did you get that from !, brilliant, I am getting odd looks from my work colleagues because I am crying with laughter in the office.

You nearly got it right, correct type of horse just the wrong colour. We are out this evening for dressage, let the squitting commence.

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AdorableAlice said:
Where did you get that from !, brilliant, I am getting odd looks from my work colleagues because I am crying with laughter in the office.

You nearly got it right, correct type of horse just the wrong colour. We are out this evening for dressage, let the squitting commence.

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It wasn't easy.... I was trying to find a link regarding your earlier post re:pooping but unfortunately that took me to a whole new place which I didn't know existed... And probably wish I didn't find.....I am now enlightened....and emotionally scarred for life....

I think this thread may have also cost me my job or marriage...I'm going to now have to try and explain my browser history....I think the company server has just crashed and I've set off every virus alert going....

All I say is don't search for anything connected.....Adorable Alice I'm going right off you! :D. Please keep your squitting habits to yourself...

Good luck tonight....!
 
OMG.....that's so sad.... As Ester said that's a lot of people getting it horribly wrong!
What on earth led to that? There's some seriously expensive kit there!
Heartbreaking!

Fortunately that wasn't us.... I was already sitting crying in a corner... Our lorry is splattered..... Adorable Alice your horse has nothing on a 17.2 horse called Wally...

He's had two trips out this weekend....and let us know exactly what he thought!

In the photo below he's giving me the evils....with a wicked grin knowing what he is about to do....

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Today we took it out again with both of the boys on....

Really really pleased overall but as always got a few jobs to do where a couple of things need to be done...I'm sure ownership will continue with continuous little jobs and alterations...

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Well come to splatt world. I had a lovely day out with the Squitting carthorse, ending in wall scrubbing with a brillo pad. Bless the little bottom burper.
 
Wow, beautiful lorry! I am very jealous.
I have just purchased my first little trailer (which is currently being serviced) and I'm so excited to get my own transport for the first time!
Would love something like this! Think I need to send this link to my dad! haha
 
Just a quick update....or rather a quick running report to detail what's worked and what has'nt.....we've done a few trips out in it now and starting to pick points good and bad...

Overall it's brilliant....driving down the road it is perfect for our two big lads! They travel perfectly in it and both joyously box without any hesitation....which is a huge relief...

It's going in for a few alterations and bits that we didn't get time to finish....

Things like a small instep into the lower skirt body by the saddle/tack locker which will just allow the girls a way of reaching the upper lock,

Little bit of rewiring of the fridge which wouldn't turn off despite turning the thermostat right down, thus would have just flattened the leisure batteries hence now putting in another isolator switch,

Only major bit of surgery that is being done is the installation of some travelling breech bars.... This will allow the horse last in to rest or lean against a pair of cushioned bars rather than standing against the rear loading doors. Before the end horse could only lean on the middle divider or the rear gates.... So the idea is a pair of breech bars that fit across the rear of the lorry that they can brace themselves on if desired..

These will also make it easier to contain the horses when the rear ramp goes down...

So we have measured up and welded a pair of mounting bars and then taken them to be powder coated properly. So these should hopefully be fitted tomorrow all being well!

Other alterations are for things that we never envisaged... The power hook up plug on the left hand side of the lorry was positioned where we thought it most convenient... Unfortunately it is in the exact place where any puddle that has gathered on the roof flows off the top of the lorry into a heavy stream...which typically overcomes the rubber sealing on the unit and fills it with water....not helpful... Wet electrics....! So have purchased some special rain guttering that can be mounted immediately above the socket which should redirect the river coming down the side of the lorry!

So overall really really pleased with what we have achieved....on a downside I would probably design more smaller storage drawers at a lower level in the living area for all the small nicknacks!....

I'll put up some photos over the next few days to show the new alterations!
 
Thank you for continuing to update even after the finish. I placed an order for a new horsebox today. 6.5t but should be plenty as we don't stay overnight. We decided on a new build as I have health issues and need things placed so I don't have to lift etc. and I need a decent seating area to rest. I've really enjoyed reading this thread and made some notes for when we get started on the build. First step is finding a good automatic Iveco LWB chassis. Fortunately I have a few weeks to decide on colour and all the other impossible decisions.
Thanks so much and I'll keep an eye out as also in the South East.
 
White is so last year.... But it doesn't show the scratches...it also helps if you work for a company that has several hundred new Transit vans painted in Ford frozen white.....:):)


As promised here are a couple of photos showing the latest running modifications....

The first shows the new breech bars mounted across the rear of the truck..these were measured at a height of our horses but have made the heights interchangeable should be ever need to carry any small ones....
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The primary reason for this is one of our horses is an Irish sports horse and he likes to stand splay legged...these bars hold him off the rear gates...

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Whilst we were doing this I also raised the kick board upto window height....previously it was just at a height whereby our 17 hands horse sat on it with his tail....rather than he using it to rub his rear end bare thought it would be advisable to raise it!
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So running repairs all round but I'm confident it's almost finished! ;)
 
Spiffy idea that...

(frantic note taking noises in background with scratchy pencil.


And noisy slurping of beverage noises too.)
 
Well really quick update and some feedback from the horses!

They love it! They now box instantly and walk straight up....in fact our Irish sport horse (the splay legged stander) is so chilled that for the first time ever in three years of travelling around the country he is now so relaxed he has actually started eating on journeys!
Before he used to worry and the haynet would never be touched....he now climbs aboard and munches his way merrily throughout the journey.

He also spends his journey now leaning against the padded breech bars so good news all round!

Only negative of changing from trailer to hgv is the pure width of the thing going down the lanes! A lot more planning of routes is needed also with things like weight limits/height limits going across and under small bridges and the like!

So for the local events we are going to keep using the old trailer....which pleases me as I won't have to pressure wash the insides after the girls have been somewhere!

All in all though it's worked out well and the advise given on this forum re needs and wants during build has been spot on! You're all brilliant! :)
 
Hi farmerchalk, after seeing your post I have took on with building one myself, I was wondering if you had any photos of how the frame was made for the tilt cab cut through. Is it bolted together? How is it sealed? Many thanks
Dan
 
Hi farmerchalk, after seeing your post I have took on with building one myself, I was wondering if you had any photos of how the frame was made for the tilt cab cut through. Is it bolted together? How is it sealed? Many thanks
Dan[/QUOTE]

Well done Dan! Use this forum for ideas as the people on here are brilliant!

In relation to your question you will need to make two frames made of angle iron or box section that are exactly the same. One bolts to the cab and roof pod and one becomes the front frame of the rear living area. They need to be dimensionally exact....and the flat faces bolt together.... The frames need to be the size of your cab and pod exactly including the cut through if your having one...

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The front one bolts to the outer dimensions of the cab area and a beam runs in the middle to assist structural rigidity along the bottom line of the pod.

Both will then need holes drilling through both frames for the bolts to run through. Consider where you are going to put these as you don't want an unsightly intrusion into the living area.. Ours are placed at the bottom corners of the pod which ties the top half of the lorry together and the bottom ones are mounted under the seating area.

Work out which way the bolts go....and weld the nuts to make them captive on the other frame.

For ease the top ones bolt through from the front so the bolt head is easily accessible from inside the pod sleeping area. The bottom bolts run in the opposite direction so the bolt head is easily accessible from under the bench seat area. You will not get easy access to the nuts once it's together hence welding the nuts to make them captive...

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The most important thing is to make sure it's all square as these frames will effectively bolt the front and back of the lorry together and stop the cab from flexing independently.....

The sealing of such is a very relevant question..... And one that I have been revising recently..... For the outer frame I just used a small thin profile about 5 mm thick which squeezes together as the frame bolts together...this seals perfectly and makes it weatherproof to stop the rain entering the sleeping pod and living area....

The recent issue I had was actually heat ingress from the engine compartment.... The heat was actually rising from the back of the engine and was trapped effectively in the ears at the side of the cab. As the heat rose it was actually entering through the gap where the cut through was....hence at motorway speeds all the engine heat was entering the lorry cab via the gap where the cut through was....

What I actually did was use a larger type of self adhesive rubber profile and placed it around the metal frame around the cut out...this has solved the cab heating problem brilliantly!

I have also cut some vent holes in the ears and now added some stainless grills to let the engine heat out properly....

The best place for the rubber profiles is a company in Tunbridge Wells called C O H Baines who supply all the oems but will sell to public... You can see there full catalogue on the Internet!

Hope this helps!
 
Thanks, just the information I was looking for. Do you know if the rubber seal is the sponge runner seal that C O H Baines has, or is it something heavier.

Thanks
Dan
 
The thicker ones I used for sealing the heat out were SRS147.....which is a collapsible sponge section but big enough to squidge together to create a seal....
The seal between the steel frames which will be visible from the outside so needs to be applied carefully (and after painting!) was SRS 136 I think. This creates a really neat seal especially as the bolts draw the two frames together....

Across the top of the lorry I added an additional bolt on aluminium extrusion which fits over seal just to make it 100% waterproof.....
Will try to find photo of such to illustrate....
 
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This photo is a better one of the frame fitted to the rear of the cab...as you can see the window for the cut out is also part of the frame which just ensures structural rigidity and helps with flexing when bolting both frames together...

We also welded a sort of metal guide affixed to the rear living frame which assists the cab to locate correctly with the bolt holes as the cab is returned from being open.... You are still going to have to wiggle the cab to get exactly lined up for the bolts to slide through properly....
 
Hello everyone....Summer season well under way now and the truck has had a few miles put on it travelling around the country at various competitions....
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just giving you an update on latest developments and words of warning/wisdom re any persons looking to purchase an HGV lorry.....

The plus side is you don't have to worry how much rubbish you load in the lorry as you're still likely to be underweight...

The downside is there is a lot more red tape owning one... Ours has just undergone its Annual MOT...sounds simple enough but, unlike a car, where you can book and MOT a car in most garages the following day .... You can't with a lorry! The MOT's are done by DVSA at a select few centres....and you need to book them months in advance...

Which I did..... However we had recently also transferred a private cherished transfer to the lorry....

Lesson number 2... Don't forget that if you transfer a cherished plate onto an HGV lorry, not only do you have to send off the normal paperwork which is simple and straightforward but you also have to get the vehicle re-plated and the tachometer recalibrated with the new index number .... I didn't ... And what a muppet I am...!

Which meant when it was presented for test, DVSA wouldn't test it as the plating certificate (which they use to identify the vehicle) now didn't match the new number plates....

Protestations abounded but trying to negotiate with them was harder than sawing off my left :o:owith a spoon.....

Anyway eventually tested it under its old registration number, getting another set of number plates with the old number to put back on the truck and then had to go through the rigamole of sending the documents back off after and getting the tachograph electronically calibrated.

Nightmare! Moral of the story.....buy a new lorry! Lol!


Anyway this week our Summer tour continues...off to Pony Club championships at Cholmondeley on Thursday travelling up from the south..

..will be there until Saturday whereby we have to do a quick turnaround...head south again just in time to spend Sunday jet washing the living area from the previous day's, and then turning around with the other horse before heading north again to Lincolnshire for the BYRDS under 25 Nationals at Sheepgate.

If anyone is going to any of those meetings, who helped with their advice and support during the build, please pop along for a chocolate hobnob and a cup of tea! Very grateful Farmer Chalk!

Love to all!
 
tul214 said:
Probably see you at Sheepgate. Wife & Daughter there Mon - Thursday. I will be making the odd appearance. Good Luck, Mark
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Excellent! Thanks Mark....I'll definately be at Cholmondeley and dependant on my sanity and workload hope to make Sheepgate... Will load it up with hobnobs though... ( and secret beer collection for the secret dad support meetings)....:)
 
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