| There are a range of ways to successfully build an Explorer Box; some more economical than others.
You can build an Explorer Box on the budget end of the spectrum for $1400 - $1500. |
|
Entry level cost of building an Explorer Box
(based on material cost
Oct ‘09) |
|
Frame |
$250 |
|
Wood |
$150 |
|
Int/Ext Finish |
$50 |
| Miscellaneous |
$170 |
| Tent Unit |
$799 |
|
| Frames |
| An Explorer Box is built on a 4’ x 6’ frame. A 4’x8’ bolt-together frame
kit is a suitable starting point. These are easily modified to be 4’x6’, available from
a number of sources and regularly on sale for under $250.Most of the lower price kits come
with 8” rims &tires, I like to upgrade to 12” rims & tires, expect to pay
$100. For a fully welded frame expect to pay around $800. I also regularly see suitable used flat bed trailers
for as little as $200 on craigslist.
|
|
| Wood |
| You’ll need about $50 worth of clear grain fir or pine 1x2 for corner and shelf blocks. You have a few trade-offs to consider when choosing your plywood.
If you go with ACX construction grade plywood, expect to pay $25 a sheet; you need four sheets. If cabinet grade Baltic Birch; expect to pay $40 a sheet, you’ll need three 5’x5’ and one 4’x8’.
I prefer Baltic Birch for the floor and cabinets, then use marine BS1088 Okoume for the exterior.
This combination saves 30-40 lbs and is very attractive with a clear finish. Expect to pay $95 a sheet for BS1088, you’ll need two sheets. Then one 4’x8’ and one 5’x5’ Baltic Birch. |
|
| Finish Type |
| This is another area with many choices. On one end of the spectrum you could go with Acrylic Latex (house) paint inside and out for around $50.
I have not personally used it for a trailer box, but if you search the internet, you’ll find a number of small boat building sites promoting its use.
If you think about it, your house is exposed to the elements day in and day out, the last time I painted mine was 10+ years ago and it still looks good.
For a durable colored exterior finish, I like a roll-on bed-liner material called Durabak. It runs about $150. For a clear interior and exterior finish, I use Target Coatings EM2000 varnish, it runs $79 a gallon.
For an added measure of moisture protection I also like to seal the exterior with Smith Companies CPES, it runs about $60. |
|
| Miscellaneous |
| There are a number of items like hardware, hinges, door latches, tongue and stabilizer jacks, glue, sandpaper, door seals, etc. that run about $170 regardless of your build method.
Basic hinges are +/- $5.00, you need five of them. The nicer stainless steel ones I like to use are $15.00 ea. There are a number of door latch options, basic barrel slide latches are $3.00 each, you need five of them.
The locking, twist cam style latches I normally use are $18.00 each. Also, if you use all stainless steel hardware expect to spend an extra $50. |
