The Trailer Build

The Trailer Build

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Building the Support Trailer

If the van is home, the trailer is the workshop, storage unit, fuel depot and “break glass in case of emergency” box on wheels.

We needed a dual-axle trailer with a 13-pin hookup and a minimum MGW of 2,000 kg, registered as its own vehicle with its own licence plate to keep everything legal internationally.

The non-negotiables looked like this:

1. Minimum internal height: 2m – so it’s usable, not just a rolling wardrobe.

2. Dual axle with its own brakes – stability and safety first.

3. A rear door that can open both as a standard door and as a ramp, or at least allow a ramp to be fitted for my wheelchair.

4. That ramp also has to make it easy to roll tyres in and out for roadside changes.

5. Roof space for a solar panel, so the trailer can have its own power system.

6. A self-contained 12v electrical system to:

   • Run the pump on the diesel tank

   • Charge my wheelchair

   • Recharge all the 18v tool batteries

7. Space for a wall-mounted rack holding two spare tyres for the van and two for the trailer.

8. Storage for tools, spare parts, emergency gear, and all the “it’s easier to bring it than find it in the middle of nowhere” stuff.

Not exactly something you just grab off the shelf at your local shop.

Enter the Debon 550XL

Then we got lucky.

We found a UK company called Debon that makes a trailer that practically ticks every box straight out of the factory: the 550XL Box Trailer.

• It has a rear door that opens like a normal door and drops down as a ramp, which is perfect for both my wheelchair and tyre handling.

• It’s the right size, the right layout, and built for the kind of work this trip demands.

From there, we adapted it to turn it into a proper support unit:

1. Upgraded the gas struts on the rear door to 12v power gas struts, so lifting and lowering the ramp becomes a button job, not a weight-lifting event.

2. Gave the trailer its own power system:

   • A 100W solar panel on the roof

   • An 80Ah lithium battery

   • A 1000W inverter for 230v power – enough to charge my chair and all the tool batteries.

3. Used the built-in multi-position clamp-down system to secure gear safely.

4. The side access door gives quick, easy access to what I need without opening the big rear door every time.

5. Added extra locks to secure all doors – because trailers attract curiosity.

6. And as a bonus, the side panels offer great real estate for sponsor names – a moving billboard with a very serious purpose.

In short: the trailer isn’t just tagging along. It’s an independent, powered support unit built to keep me rolling, fixing, charging, and surviving across multiple countries for two years.