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  1. #1

    Custom Karavan Trailer

    Hey guys thought I'd share my creation. In Dec 2016 I bought a '16 RXT-X with an all aluminum Magic Tilt PWCV1250A. I had wanted an aluminum trailer for the ski but the Magic Tilt didn't cut the mustard. My big issue with most PWC trailers on the market is they don't fit the bigger 3 seaters like my RXT-X very well. If I was going to spend the coin to replace a perfectly good trailer, I wanted it to be BEEFY, and go all the way to the transom of my ski. I searched std offerings from every manufacturer under the sun and also considered a custom build from EZ Loader, which was quoted as "at least $3k" for what I wanted. Yes even the coveted Tritons are too short, and wouldn't have been worth the upgrade.

    Finally found Karavan's offerings including the WCA-1500-56...which is an I-beam trailer with dimensions better suited to a large ski. The problem...my Texas distributor said it would be late August to get one. So I figured out Karavan has an almost identical trailer called SL-1500-56 that would be a good starting point. Frame, torsion axle, 13" wheels/tires are all identical to the WCA-1500, just has bigger bunks, better winch stand, and a longer tongue to fit a small boat. These were also tough to find, but I located a '16 model in FL for a steal at $1250.

    Here's a list of my mods to the standard Karavan SL-1500-56:
    1) Polished I-beams (sat in FL sun for a year, needed some TLC)
    2) Cut 28" off tongue, leaving overall length 16' (about 1' longer than WCA-1500)
    3) Replaced bunks with 6ft 2x4 bunks
    4) Upgraded Fulton F2 Jack and Winch
    5) LED Tail Lights (I believe this is standard now)
    6) LED Markers in I-beam
    7) 7-Way Coiled Bargman connector, wired for future reverse lights
    8 Curt 80151 Coiled Safety Cables (stock were already rusting)
    9) Flat Black Vinyl inside I-beam
    10) Premium Line-x coating on fenders, tongue, tongue cross member, winch stand, and tail light housing
    11) Sendel T06 15x6 0mm offset wheels, w/stainless hub covers
    12) Kumho Ecsta 4X 195/55R15 tires
    13) Boat Buckle tie-downs
    14) Black 40" Guide posts (mainly for backing while empty)
    15) All stainless u-bolts
    16) Many other zinc bolts to replace stock galvanized

    Pics below, let me know what you think!

    Original Magic Tilt PWCV1250A:




    Stock SL-1500-56



    Finished product:








    Last edited by Shaggy97; 06-25-2017 at 10:39 PM.


  2. #2
    wakejunkie's Avatar
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    Trailer looks great!!!! I like the safety chains and wiring. I always wrap my chains around the tongue on mine. Might upgrade to these chains.

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  4. #3
    Click avatar for tech links/info K447's Avatar
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    Quote Originally Posted by Shaggy97 View Post

    Here's a list of my mods to the standard Karavan SL-1500-56:
    ...
    15) All stainless u-bolts
    16) Many other zinc bolts to replace stock galvanized

    ...
    Did you mean stainless steel bolts to replace galvanized?

  5. #4
    Quote Originally Posted by K447 View Post
    Did you mean stainless steel bolts to replace galvanized?
    No I meant zinc plated. Had some issues with SS bolts from Home Depot that I needed for the bunk brackets and winch stand so went to zinc as an alternative. The SS nuts would cross-thread and lock up when I tried to back them off. Have experience with zinc that I should know about?

  6. #5
    Click avatar for tech links/info K447's Avatar
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    Quote Originally Posted by Shaggy97 View Post
    No I meant zinc plated. Had some issues with SS bolts from Home Depot that I needed for the bunk brackets and winch stand so went to zinc as an alternative. The SS nuts would cross-thread and lock up when I tried to back them off. Have experience with zinc that I should know about?
    Stainless Steel bolt and nut threads can gall, especially if torqued really tight. Galled threads can effectively lock the nut onto the bolt, preventing it from turning.

    Zinc plating is generally a thinner coating of zinc compared to 'galvanized', which is a thicker zinc coating on the underlying steel.
    https://www.electronicfasteners.com/...nd-galvanized/

    Which is why I wondered about your replacing the galvanized bolts with zinc plated.

  7. #6
    Why did you replace the bunks? Could you just have shortened them in the back and or slid them forward?

    Thanks,
    Mike

  8. #7
    steve45's Avatar
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    Looks nice!

    Always a good idea to put a little grease on threads of stainless steel. You never know what grade of SS you're getting at the box stores.

  9. #8
    canuck's Avatar
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    Looks good.

    I bought the WCA-1500-56 watercraft trailer a few years ago for the same reason the bigger skis fit much better. Spare tire, Boat Buckles and proper safety chains are the only upgrades on mine. That winch post on yours is nice might need to upgrade mine now.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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