Project 2 Enclosed Trailer Rear Door Height Modification

Here is something i need to do before the weather changes, Our mule is too tall to go inside the trailer.We need 2.5" now to get the mule in but will add as i have room for.Looks like there is enough in the rear header above the door to add about 4" or so to the opening height.I removed the doors and trim this afternoon and will cut out the old header and add a new one.Will try to get this done this week.The rear aluminum trim was all screwed around the rear opening ,as you can see they used no sealant and the corrosion has started to eat away, I plan on putting on new door skins when the doors are made larger and maybe a new rear skin also . Here are some pics of the problem and possible remedy.


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Got the opening cut this morning , Used a saw to keep sparks from getting behind the walls, Added a new brace and upright to the inside of the header out of 1" 11ga square tubing, Will get that welded up and add a gusset on each side and put on the trim and start on the new doors.

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I live in a mecca where a lot of these trailers are produced. Not much to it is there?

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Originally Posted by performance

I live in a mecca where a lot of these trailers are produced. Not much to it is there?

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No there is not they do not use anything extra, This trailer was ordered special by myself and picked up at the plant i watched it go down the line. The rear doors are just a perimeter frame of wood with a few roofing staples holding them. I chose to use 3/4" hardwood plywood for the new ones then laminate the 6mm backer on and the front and rear aluminum skin to get to 1". I just ordered the new perimeter trim from Forest River for the door edges.Of to pick up some Meds and order a pint of paint to match the color of the trailer.

Here is all the progress for the day, A couple of pics of the doors being laminated with plywood and the inside lower aluminum skin and the outside skin, Door material is 18mm 11 ply hardwood plywood with a 6mm plywood laminate inside ,Aluminum skin was .90mm .They are of to paint the matching silver and get installed in the morning.Fedex should have my new door trim by Thursday afternoon to finish up.Will add some new clearance lights and the drip rail to the header in the morning.
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Originally Posted by cbmkr

Here is something i need to do before the weather changes, Our mule is too tall to go inside the trailer.We need 2.5" now to get the mule in but will add as i have room for.Looks like there is enough in the rear header above the door to add about 4" or so to the opening height.I removed the doors and trim this afternoon and will cut out the old header and add a new one.Will try to get this done this week.The rear aluminum trim was all screwed around the rear opening ,as you can see they used no sealant and the corrosion has started to eat away, I plan on putting on new door skins when the doors are made larger and maybe a new rear skin also . Here are some pics of the problem and possible remedy.


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Looks like alot of WORK
I would have just let the Tyres Down lol:P

We tried that and i was not successful ,We even put a lot of weight in the back. Right after i ordered it years ago i wished i had added 8" in height instead of 6.The doors on most of these are made of wood this trailer has a lot of miles on it probably around 90-100K ,It needed new doors made and then the mule came along and would not fit, if i have to build new doors just as well make the opening bigger. As it would be the opening took a lot less time than the doors . It will work out ok in the end as it is a lot cheaper than ordering a new one and if i can do it for 4-5 hours in a couple days it will be worth it.

Here it is all back together , i had to order new extrusions for the door edges and trailer sides, they came in this morning so i finished up the doors ,Reinstalled them added some new clearance lights and we are ready,I did have to use the Power Tig 185 ,The z channel that came was the wrong size so i cut up some .050 aluminum and made my own extensions for the door opening.They were a little pain to weld the 7 year old material to the new but it worked out.All the door edging and trailer trim is now sealed to keep moisture from getting in.Here are a couple of pictures.Attachment 7765Attachment 7766Attachment 7767

Thought i would load up and see how much room i have now cleared by 1 3/4" . Now i can make those 6-7 hour drives in the fall and winter and not have to worry about rain and snow and all the salt spray getting all over everything.Not to bad on price a little over $200.00 in material with the plywood aluminum skin and the extrusions i had to order.Saves buying a new trailer.Attachment 7769

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Originally Posted by cbmkr

Thought i would load up and see how much room i have now cleared by 1 3/4" . Now i can make those 6-7 hour drives in the fall and winter and not have to worry about rain and snow and all the salt spray getting all over everything.Not to bad on price a little over $200.00 in material with the plywood aluminum skin and the extrusions i had to order.Saves buying a new trailer.Attachment 7769

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Until you put bigger tires or a suspension lift on the Mule. :D

Looks nice, and I'm sure getting things sealed will really extend the life.

Nice work, it's better than new now.

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Originally Posted by cbmkr

Our mule is too tall to go inside the trailer.We need 2.5" ...

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Hate to admit this, but the first thing that popped into my head was 'why can't the durn thing just duck his head?' Then I saw the pics.Attachment 7770

That turned out real nice, good job.

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Originally Posted by Scotty1

Looks like alot of WORK
I would have just let the Tyres Down lol:P

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That is exactly the first thing that poped in my head.

It does look like it was a lot of work but since the doors need changing anyways, well worth the effort. You did a great job by the way.