Seeking Feedback on Tongue Box Design

[OffWeGo]

To all of you seasoned, innovative Oliver owners...  I would love to get feedback and insights on a tongue box design I'm working on.  We've only owned our Oliver since November 2023 and we've camped about five weeks total so far and really love our LEII.  We're planning a two + month trip this summer and I'm struggling with a versatile box design for the front.  I've seen the product made by Seabiscuit and it's very well made.  I would like to take it a step further and enclose the tongue jack and divide the box into a bottom section for a Honda 2200 generator and a removeable top shelf for chocks, blocks and other lightweight items.  Please take a look at my sketches and let me know what you think.  Thank you all in advance for your feedback.  I really enjoy discovering all the creative mods posted here on the forum.

FRONT BOX DESIGN.pdf

[jd1923]

2 hours ago, OffWeGo said:

Please take a look at my sketches and let me know what you think.

We're good with just our basket up front since we only store a fire ring up there, don't carry a generator. There are others here who have given this much thought and those who have installed front boxes.

One thing that stands out to me re your idea and drawings is the LP doghouse cover. On our older hull there is just enough room to replace the cover getting it by the jack head. It seems to come off easier than it goes back on. You have likely not removed that cover too many times yet. I would take it on and off a couple times and give some thought to required clearance.

Have fun on your 2-month trip! 😎 

[Geronimo John]

I presented an almost exact idea to Seabiscuit at the 2025 OTT Ralley.  You need to add a screened bottom to allow fumes to sink down and out and provide up draft ventilation.  I personally would keep side penetrations closed unless running the generator.  Also top to shield rain unless running generator.

The Honda generators are weather protected.... not weather proof.  Found that out the hard way....

You may want to give them a call to see where they are/are on the idea presented to them at the rally.

GJ

[OffWeGo]

Thank you both for the helpful tips!  I might see if I can Frankenstein something together on my own.  If I get something made I'll post pictures.  

[dhaig]

@OffWeGo, I reviewed the sketches you provided for the Front Storage Basket and offer the following comments:

• Placing the unit in front of the dog house will move you 26" away from the cover on the doghouse.  This will likely make removal of the doghouse cover difficult, if not impossible for one person when propane tanks must be refilled.  To remove the doghouse cover on my 2022 LEII I straddle the tongue of the trailer and am able to reach the handles on both sides to lift it. 
• Some clearance space will be needed between the front of the doghouse and the rear of the storage unit for clearance of the doghouse cover when dis-mounting and mounting.  If the top of the storage unit is hinged at the rear, space will be needed to avoid hitting the top of the doghouse.
• No details are included to show how the storage unit is to be mounted.  The indicated mounting positon places the storage unit on top of the fiberglass covering the trailer tongue.  The fiberglass would need to be drilled for passage of mounting bolts. You would likely need spacers to keep the storage unit from resting on the fiberglass and potentially cracking it.  You would need to tap into the aluminum frame members or use long "U" shaped bolts to secure the storage unit to the frame.  As I recall, Oliver uses long "U'" bolt to secure the front storage tray they offer as an option.
• The storage unit design has a lot of doors (2 side, 1 front, 1 top).  This presents a challenge for the frame of the unit to have sufficient rigidity to support the doors.  To have sufficient rigidity you may have little choice but to have a square tube  inner frame.   Having the tubing presents an obstacle to installing and removing the generator, as you have noted.  Also, securing all of the door to prevent theft will be a challenge.   The top will need a gas cylinder or other support to hold it open,
  • I had an outdoor grill stand fabricated from stainless steel to support a 200 lb grill.  My initial design used square tubing to be clad with stainless steel sheeting.  I took the design to an experienced fabricator, who recommended eliminating the square tube frame and building the stand using stainless sheet only.  This change produced a much better result.  There are storage areas on each side of the grill and they have stainless steel doors.  The unit is quite stiff and strong.  If you are interested I can provide photos of the details.
•  How is the removable shelf to be supported? "L" shaped brackets mounted to the inside of the unit could work.  The mounting method could be either bolting or welding.
• Your sketch lists routing of the power cable from the generator to the shore power connection on the street side of the doghouse.  You might consider attaching a weathertight electrical box containing a 15 or 20 amp outlet on the exterior of the storage unit, with a short cable running through the wall into the generator.  I suggest making a short cable that would connect from the weathertight box outlet to the shore power inlet.
• How accessible are the pull starter, choke and controls on the generator when in the storage unit?  I have used small Honda generators before and they are usually relatively easy to start, but I never tried starting one in a confining box.

I suggest you reconsider having the generator mounted in a storage unit on the trailer tongue, for several reasons:

• Mounting the generator to the trailer frame will likely transmit vibrations along the frame which will be noticeable in the cabin.  The same concern for noise.
• Having the generator exhaust so close to the cabin presents a danger of infiltration of carbon monoxide into the cabin.
• Overheating is likely to be a problem running inside the storage unit, even with all of the openings.
• Additional tongue weight may become an issue.  I don't know the tongue weight limit for your Tundra.  The generator, storage unit and chocks could add 60-75 pounds.
• I try to locate our generator as far as possible from the trailer, considering neighbors, wind direction, etc.  I use a 25 foot propane hose to connect our generator to the low pressure propane connections on the front and rear of the trailer.

I elected not to install any type of cargo carrier on the trailer tongue, primarily to keep the tongue weight within the limits of our tow vehicle, a BMW X5 35d (diesel).  I did not like the cargo tray offered by Oliver- too small to meet our storage needs and too difficult to secure.  Instead, I installed a rear mounted cargo carrier.  The generator, a grill, chocks and Starlink case are accommodated.  You can find a write-up on the details here: How To Install a Rear Cargo Carrier on an Oliver Legacy Elite II.

Good luck with your project!

Regards, Don 

[OffWeGo]

Thanks Don, excellent feedback!

[dewdev]

Not sure if this is of any help, but I have attached the dimensional drawing for the Oliver front box, FYI.