Building a leaf box for your dump trailer is a highly effective way to significantly increase its hauling capacity, especially during fall cleanup or for landscaping businesses. This modification dramatically expands the volume you can carry, reducing trips and boosting efficiency. This comprehensive guide will walk you through the process, providing detailed instructions, material lists, and helpful tips to ensure a successful build.
Understanding the Benefits and Challenges of a Leaf Box
A leaf box, essentially an extension to your dump trailer’s sides, transforms it into a high-capacity hauling machine. It’s particularly useful for bulky, lightweight materials like leaves, grass clippings, brush, and even wood chips. However, before diving into construction, it’s crucial to understand the pros and cons.
Advantages of Using a Leaf Box
- Increased Capacity: The most significant benefit is the dramatic increase in hauling volume. This translates to fewer trips to the disposal site.
- Time Savings: Fewer trips mean less time spent driving and unloading, freeing you up for other tasks.
- Cost-Effectiveness: Compared to buying a larger trailer, a leaf box is a much more affordable option.
- Versatility: While designed for leaves, a leaf box can handle various lightweight materials, making your dump trailer more versatile.
Potential Drawbacks to Consider
- Height Restrictions: Adding height to your trailer can create clearance issues under bridges, overpasses, and tree branches. Always be mindful of overhead obstacles.
- Wind Resistance: A large leaf box presents a significant surface area to the wind, potentially affecting handling, especially when empty.
- Material Weight: While lightweight, the materials used to build the box will add to the trailer’s overall weight, potentially reducing its payload capacity for heavier materials. Always check your trailer’s GVWR (Gross Vehicle Weight Rating) and ensure you stay within its limits.
- Storage: When not in use, the leaf box needs to be stored, which can be challenging depending on its size and construction.
Step-by-Step Guide to Building Your Leaf Box
This guide assumes you have a basic understanding of metalworking and woodworking, including welding, cutting, and drilling. Safety is paramount, so always wear appropriate safety gear, including eye protection, gloves, and hearing protection.
1. Planning and Design
- Measure Your Trailer: Accurately measure the inside dimensions of your dump trailer bed. This is critical for ensuring a proper fit.
- Determine Desired Height: Decide how high you want your leaf box to be. Consider height restrictions and wind resistance. A common height is 2-4 feet above the existing trailer sides.
- Choose Your Materials: Options include steel tubing, angle iron, and plywood or expanded metal for the sides. Steel is generally more durable, while wood is lighter and easier to work with. Aluminum is an expensive but lightweight option. For this guide, we’ll focus on a steel frame with expanded metal sides.
- Create a Detailed Plan: Draw a detailed plan, including dimensions, materials, and welding locations. This will serve as your blueprint.
2. Material Procurement
Based on your plan, purchase the necessary materials. Here’s a general list:
- Steel Tubing: (e.g., 1″ x 1″ square tubing) for the frame. Calculate the amount needed based on the perimeter of your trailer and the height of the leaf box.
- Angle Iron: For reinforcing corners and attaching the box to the trailer.
- Expanded Metal: For the sides of the box.
- Welding Wire/Rods: Appropriate for the type of steel you’re using.
- Primer and Paint: To protect the steel from rust and corrosion.
- Fasteners: Bolts, nuts, and washers for attaching the box to the trailer.
- Safety Gear: Eye protection, gloves, hearing protection.
- Cutting and Grinding Discs: For metalworking.
3. Frame Construction
- Cut the Steel Tubing: Using a metal cutting saw or angle grinder, cut the steel tubing according to your plan. Ensure accurate cuts for a square and sturdy frame.
- Weld the Frame: Carefully weld the cut pieces of steel tubing together to form the frame. Ensure strong, clean welds. Use angle magnets to hold pieces in place during welding.
- Add Reinforcements: Weld angle iron to the corners of the frame for added strength and rigidity.
4. Installing the Expanded Metal Sides
- Cut the Expanded Metal: Measure and cut the expanded metal to fit the frame. Use a metal cutting saw or angle grinder.
- Weld the Expanded Metal: Carefully weld the expanded metal to the inside of the steel frame. Ensure proper ventilation when welding galvanized metal, as it releases harmful fumes. Consider using a wire feed welder for easier control.
5. Attaching the Leaf Box to the Trailer
- Determine Attachment Points: Identify strong points on your trailer frame or sides to attach the leaf box.
- Drill Mounting Holes: Drill holes through the steel frame of the leaf box and the chosen attachment points on your trailer.
- Bolt the Box to the Trailer: Securely bolt the leaf box to the trailer using bolts, nuts, and washers. Consider using lock washers to prevent loosening due to vibration.
6. Finishing Touches
- Grind Welds: Grind down any sharp edges or rough welds.
- Prime and Paint: Apply a coat of metal primer to the entire frame, followed by two coats of exterior-grade paint. This will protect the steel from rust and corrosion.
- Inspect and Test: Carefully inspect all welds and fasteners. Test the leaf box by loading it with a small amount of material and taking a short drive.
Frequently Asked Questions (FAQs)
FAQ 1: What’s the best material for a leaf box frame?
Steel tubing offers the best combination of strength and durability for the frame. While wood is cheaper and lighter, it’s less resistant to damage and weather. Aluminum is an excellent lightweight option but significantly more expensive.
FAQ 2: How high should I make my leaf box?
A height of 2-4 feet above the existing trailer sides is a common and manageable range. Consider height restrictions and wind resistance when making your decision. Taller boxes can be more susceptible to wind and require more robust construction.
FAQ 3: Can I use plywood instead of expanded metal for the sides?
Yes, plywood is a viable option, especially if you’re looking for a lighter and more cost-effective solution. However, it’s less durable than expanded metal and requires regular maintenance to prevent rot and water damage. Consider using marine-grade plywood for increased weather resistance.
FAQ 4: What type of welding is best for building a leaf box?
MIG (Metal Inert Gas) welding is generally recommended for its ease of use and clean welds. Stick welding (SMAW) is also suitable, but requires more skill. TIG (Tungsten Inert Gas) welding provides the cleanest and strongest welds, but is the most complex and time-consuming.
FAQ 5: How do I prevent rust on my steel leaf box?
Thorough surface preparation is crucial. Clean the steel thoroughly with a degreaser, sand or grind off any existing rust, apply a coat of metal primer, and follow with two coats of exterior-grade paint. Consider using a rust-inhibiting primer for added protection.
FAQ 6: What size bolts should I use to attach the leaf box to the trailer?
The appropriate bolt size depends on the thickness of the steel and the load-bearing capacity required. A general guideline is to use grade 5 or grade 8 bolts with a diameter of at least 3/8 inch. Consult a structural engineer if you’re unsure about the load-bearing requirements.
FAQ 7: How do I ensure the leaf box is securely attached to the trailer?
Use multiple attachment points and ensure they are evenly distributed along the length of the trailer. Use lock washers to prevent bolts from loosening due to vibration. Regularly inspect the bolts and tighten them as needed.
FAQ 8: Is it necessary to get a permit to use a leaf box on my dump trailer?
Permit requirements vary depending on your location. Check with your local Department of Transportation (DOT) to determine if any permits are required for increased trailer height or overall vehicle dimensions.
FAQ 9: How do I handle the extra height of the leaf box when driving?
Be mindful of overhead clearances, such as bridges, overpasses, and tree branches. Avoid driving in areas with low-hanging obstacles. Adjust your driving speed to account for the increased wind resistance.
FAQ 10: Can I build a removable leaf box?
Yes, a removable leaf box is a practical option for those who need to switch between hauling leaves and other materials. Use a system of brackets and pins to securely attach and detach the box.
FAQ 11: What are some safety considerations when using a leaf box?
Never overload the trailer. Ensure the load is evenly distributed to prevent tipping. Secure the load with straps or netting to prevent materials from blowing out. Be aware of wind conditions, especially when the box is empty.
FAQ 12: How much weight can my leaf box handle?
The weight capacity of your leaf box is limited by the GVWR (Gross Vehicle Weight Rating) of your dump trailer. Subtract the weight of the trailer and the leaf box from the GVWR to determine the maximum weight you can haul. Never exceed the GVWR.