From Weld to Finish: Watch a Double D Trailer Being Built from the Ground Up!
Did you know? It only takes 10 to 12 days to build a Double D Trailer. Plus, every single horse trailer that rolls out of the Double D Trailers factory has been built to match the specific requests of a certain customer.
That’s what makes our trailers so special. They combine top horse safety features with truly expert craftsmanship for one-of-a-kind models that are sure to attract attention and service your needs for years to come.
We’ve put together this factory tour to show you all of the steps that go into building one particular trailer from weld to finish. This particular model is a SafeTack Reverse 3 horse bumper pull trailer. Check it out!
Or, read below for a step-by-step explanation of what's going on in each image.
Trailer construction starts as most things do…from the ground up… This is a Z-Frame chassis being constructed on a "jig". In this image, the axles have not yet been mounted yet and the chassis is actually upside down on the frame. The Z-Frame cross members are placed approximate 16-inches apart for strength.
After the wheel axles have been mounted, the entire chassis is flipped over using an overhead crane system.
The chassis is placed on the ground and positioned so that the rest of the trailer can be constructed using it as a base.
The tubing uprights are placed to start framing out the trailer. Since every trailer is custom built for a particular customer, the dimensions of the trailer will be unique to each design. Notice the front dress flooring is actually higher off the ground than the
horse flooring. This eliminates a "toe trip" door entry way to your dress, plus makes it easy to "sweep out" dirt.
Also makes it easier to remove a horse area floor "board" in the future should one require maintenance.
The tubing uprights that form the walls of the trailer are also built of Z-Frame material so they provide a very strong frame for the whole structure. Here, you can see the front end of this trailer with the trailer tongue and coupler in place.
The flooring has been placed in this trailer. This is an example of Rumber flooring which is a third-party product that we recommend in our trailers. It is a synthetic material that fits together in a tongue-and-groove system. It is easy to clean and transfers minimal heat and vibration up from the road. Best of all, you’ll never need to use those heavy mats with Rumber flooring!
Z-Frame is a patented technology that we developed to offer superior strength over steel or aluminum frames. The material is impregnated on the inside and outside with chromate and zinc. This makes it incredibly strong and still light-weight.
The skin of this trailer is constructed from a two-layer system with a layer of 0.04 aluminum on the outside (not shown yet) and 18-guage Galvalite on the inside. The lower kick walls are prepped to receive the "Safekick" wall system later down the production line.
Every Double D Trailer with a dressing room comes standard with an interior door from the dressing room to the horse area.
Here, you can see the back of this trailer. The Galvalite skin has been mounted, polished, and the SafeTack compartment is being framed out.
The side dressing room door has been mounted and the trailer is almost ready for its outer skin of aluminum.
Here, you can see the first look at the ramp on the back of the trailer. Our ramps are spring-loaded so they are easy to lift into place. We also mount them at a reasonable angle and cover them with a non-skid surface so they are safe for horses and humans to walk upon without slipping.
The SafeTack compartment now has its interior lining.
The side ramp has also been mounted here for this Reverse SafeTack trailer. Horses will be able to load from either the side or the rear ramps. If they load from the side, they can walk back into their rear-facing stalls. To offload, they will simple walk straight off the rear ramp of the trailer.
Interior dividers made of Z-Frame material have been added in this photo. They have tubular head dividers for maximum air and light flow.
Prior to the aluminum skin being installed, the entire chassis is sprayed with an epoxy primer for protection and smooth
finish. The exterior skin has been added to the trailer and it's secured using a 3M Chemical bonding system which is a
water tight method that uses no mechanical fasteners such as bolts, screws, or rivets.
Notice that the trailer doesn’t yet have wheel wells, windows, or any door fasteners. There’s still lots of work to do!
Yikes, and no roof!
The SafeBump roof has been added in this photo. Our single piece fiber composite roof is designed to protect your horse if they strike their head on the ceiling. It also keeps a safe temperature inside the trailer on the hottest of days. A Z-Frame support is built into the roof every 16-inches to provide superior strength. Since it's "one piece", you never have to worry about leaks.
Paper panels are hung to protect the trailer during the next phase of painting. This trailer is showing a classic grey and black color scheme, but other customers have opted for brighter colors like blue, purple, and even pink!
Wow, quick change on the paint scheme. The aluminum running boards have been added to the side of the trailer. In addition, this image shows that the drop down windows have been installed on the side. Our windows feature a mid-latch system so they can be easily opened. The windows have a rubber gasket on their outer edge so they are reliably leak-proof. The glass and bar portions can be lowered independently and a screen can be added as an option.
It’s time to add all of the final touches! Here you can see that the spare tire, door fasteners, and wheel wells have been added. This model also has a ladder with a hay rack mounted on the roof.
The trailer has interior lights in both the horse compartment and in the SafeTack compartment shown here. In addition, all trailer doors can be locked or unlocked with a single key for security. Initially, the frame was covered with a gray epoxy. And the final interior color white along with black roof rail/chassis accents. You may select your chassis accent color at no additional cost.
Everything seems to be in good working order, so it’s time to roll this beauty out of the factory doors.
Voila! A finished Double D Trailer that is ready to go! We have a flat rate delivery system to anywhere in the continental US. Delivery options are also available for Canadian, Mexican, and Australian customers.
One of our delivery drivers (Kelley) is now on her way to deliver this trailer to its proud new owners! Delivered to http://www.bbranchfoundation.org/ in Glendora, California.
If you are interested in designing your own horse trailer with Double D Trailers, don’t hesitate to reach out to owner Brad Heath. He’ll be able to answer all of your questions. Thanks for joining us on this factory tour!