Handmade Items: It’s NOT Just Materials Cost

I explain why I charge $39 for a pair of earrings with less than $10 worth of materials.

Yesterday, I went down into my jewelry shop and made 6 pairs of earrings out of roughly $55 worth of sterling silver sheet metal and pre-made ear wires. I’ll sell each pair for $39. Sounds like a great deal for me, right? Well, if you read on, you’ll learn more about the actual cost of these earrings.

I tweeted my progress while creating these earrings, using a Twitter thread with photos. I skipped tweeting the first step, which was getting the pattern onto the silver — I don’t buy sheet silver with a pattern already on it (although I do sell it that way) — but got most of the other steps. They make up good documentation for this blog post’s purpose, which is to talk about what actually goes into making something from scratch: materials, tools, skills, and time.

Materials

The materials for this project were pretty basic:

  • 26 gauge sterling silver sheet. I buy the metal I plan to apply a pattern to in 6″ x 2.5″ pieces because that’s the size of most of my texture plates. I learned (the hard way) that you can ruin a texture plate by using it to texture a smaller piece of metal than the plate. Because of a 75% or so increase in the price of silver last year, this small piece of metal cost just over $42.
  • Sterling silver ear wires. I buy these in bulk, but they still cost nearly $1 each. I can save money by making them myself out of 20 gauge half-hard sterling silver wire, but I like the look of the ones I buy and they’re less likely to bend out of shape than the ones I make. I’ve even had one of the galleries I provide inventory to tell me that they prefer manufactured ear wires for the very same reason.
  • Rubber ear nuts. These are tiny pieces of rubber that go onto the end of the ear wire, making them less likely to fall out of your ear (or off the jewerly display card I use when selling). I buy them by the gross and they cost a fraction of a cent each. (I don’t understand why all jewelry makers don’t include them with ear wire earrings. Such a tiny, inexpensive little thing can prevent the loss of earrings.)

In addition to these materials. I also have the printed cards I use to display and sell the earrings. These cost just pennies apiece and are part of my marketing/selling expenses, but they shouldn’t be overlooked. Ditto for the specially sized, clear plastic zipper bags I put the earrings and cards into when I sell.

Tools and Equipment

It’s the tools and equipment that really add to the cost of the jewelry I make. As an accountant might tell you, these are fixed costs that need to be considered as part of anything you make with them. The more you use a tool or piece of equipment, the less the per-piece cost of that equipment is. An analogy from my day job as a pilot would be something like insurance: if it costs you $15K/year and you fly 100 hours a year, that’s $150/hour; but if you fly only 10 hours, that’s $1500/hour. Ouch.

Going through the steps to create these earrings, I used the following tools and equipment:

  • Rolling mill. This is the device I used to impress the pattern onto the silver. Rolling mills vary in cost. I have a Durston, which is made in the U.K. and isn’t cheap. But mine is small, so it wasn’t too costly. I think I paid around $750 for it.
  • Texture plate. This is a piece of brass with a texture on it. The brass is harder than the silver so when the two pieces of metal are run through the rolling mill together, the texture from the brass is imprinted onto the silver. The texture plates range in price from about $5 for a single-use paper version up to $100 or more for steel versions. My brass plate cost about $10 and will give me about 50 impressions before it’s too flat to make more impressions.
  • Metal shear. Although I didn’t really need it for this project, I used my metal shear to cut off a 1/4″ by 2 1/2″ piece of the textured metal to use as a ring blank. You see, when the metal goes through the rolling mill, it stretches. So even though I cut 1/4″ off one end, I still had 6″ x 2 1/2″ of textured metal to work with. My metal shear, which I use a lot, cost about $250.
  • Shape template. I use shape templates to create earrings and other items in consistent sizes and shapes. The template I used for this project has about 30 shapes/sizes on it and cost $8. It’s made of heavy duty plastic so it’ll last a long time.
  • Fine point Sharpie pen. That’s a tool, too. I used it to trace the shapes onto the metal as close as I could without overlapping. What do they cost? About $3 each?
  • IMG 0028
    Here’s the cutting job in progress.

    Joyce Chen kitchen shears. I have a variety of ways to cut metal sheet — my jeweler’s saw, a pair of French shears — but I used these shears for this project. They’ll cut through any reasonably thin soft metal — and 26 gauge silver is pretty thin and relatively soft. The cost? $21.

  • Flex shaft. After cutting out all those pieces, I needed to smooth their edges. Being the machine person I am, I used my flex shaft, which is basically a Dremel-style tool with the motor at the end of a long shaft and a foot pedal to control the speed. Mine is a EuroTool and cost about $120. But don’t forget to add the motor hangar for it, which cost another $32.
  • Mounted sandpaper cartridge roll. I used a sandpaper roll to do the actual sanding. They cost about $1 each.
  • IMG 0032
    Here’s my custom dapping block. The other drawn-on shape is for one I no longer use and never actually carved into the wood.

    Custom dapping block. A dapping block makes it possible to put a dome into pieces of metal. But because these earrings aren’t round, they needed a custom dapping block. I made mine from a piece of bass wood that only cost about $2, but I used a variety of Dremel bits to carve it out and I fine-tune it every time I use it. Still, we’ll say $2 for this homemade tool.

  • Nylon hammer. Although my photos on Twitter show me using a dapping punch with the block to put a dome on the metal, I actually used a domed nylon hammer that has always worked a little better for me. Cost: $14.
  • Hole punch. While I could have drilled holes for the ear wires into each piece before doming it using a center punch, flex shaft, and drill bit, I took the easy way with a 1.25mm metal hole punch. Cost: $14.
  • Scrap wire. I used a piece of thin copper wire to attach the earring pieces together for oxidizing them. The cost of this scrap is pennies and not even worth adding into the equation.
  • Using Liver of Sulfur
    In this shot, I’m dipping all 12 pieces of the earrings, on a copper wire, into the liver of sulfur. You can see the jar and mug warmer, as well as the side of the container next to it that I use for the baking soda rinse.

    Liver of Sulfur. Liver of sulfur is a chemical that, when dissolved in warm water, can darken copper or silver (but not gold). It’s widely used by jewelers who want an oxidized look on textured metal. The stuff I use costs $18/jar and that’ll last about a year.

  • Mason jar. I use a 1-pint wide mouth mason jar to mix, heat, and store the liver of sulfur. Because I do canning, I always have a bunch of spare jars — although once I use them for chemicals, I can’t wash and reuse them for food. Figure about $2 for this jar with the plastic lid.
  • Cup warmer. I use a coffee mug warmer to keep the liver of sulfur warm while working. The one I use costs $11, but you can sometimes find them cheaper in thift shops.
  • Baking soda. I mix baking soda and water in a glass bowl and use that to neutralize the chemical reaction of the liver of sulfur so the metal stops darkening. It’s the stuff you buy in the supermarket. How much? I don’t know. $3 for a box that’ll last a very long time?
  • Container. Of course, I need a container to put that baking soda and water solution in. I use reusable disposable plastic containers with lids. When I’m done, I cover it up so it doesn’t evaporate. Figure $2 for a container with a lid.
  • Tumbler. There are all kinds of tumblers you can use for jewelry, but I use a basic Lortone 3A 3-lb capacity rock tumbler. I paid about $110.
  • Ceramic tumbling media. This is my secret sauce and I’m not very motivated to provide details, mostly because it saves me a ton of work and provides consistent results every time I use it — which is vital when you need to make multiples that are the same. Let’s just say that it’s ceramic tumbling media that rubs the darkening off the raised part of the pattern. The stuff I use costs $45/bag and that bag will last at least a year. If you want to try it, find one that works for you. (Good luck.)
  • Dawn detergent. I add a drop or two of Dawn to the tumbler with the ceramic media and water. I always use dawn because everyone recommends Dawn. I buy small bottles that last a long time. What does that cost? Let’s say $2.
  • Extra tumbler barrel. Because it’s best to keep stainless steel shot separate from any other tumbling media, I had to buy an extra barrel. Add $36.
  • Stainless steel shot. Steel shot burnishes the finished jewelry. Don’t buy the cheap stuff; it’ll rust. I buy it by the pound for $26; because it doesn’t rust, it should last forever.
  • Burnishing compound. A few drops of burnishing compound in the tumbler with water and the steel shot helps achieve a nice polish. It’s $10 for an 8 oz. bottle that lasts at least a year.
  • Earrings
    I finished the earrings in my home at my breakfast bar while waiting for dinner to cook.

    Chain nose pliers. I use pliers to open the ear wire loops and close them once the earring piece is attached. My preferred brand: Wubbers. They’re not cheap but they’re heavy duty. $26.

  • Paper hole punch. I use a small punch to put holes in the cards that I mount earrings on. Figure about $9.

That’s everything I used directly during the course of this project. It doesn’t include rags or paper towels or the wipes I use to keep my workspace clean after sanding. It doesn’t include any of the furniture in my shop — my homemade jeweler’s bench, the tables where I keep my rolling mill and soldering station (where the liver of sulfur lives), or my adjustable height stool. It doesn’t include lighting and utilities for my shop space. Heck, it doesn’t even include the cost of constructing my shop space, which is an entire 12 x 24 foot room in my garage.

Let’s add these costs up:

ItemAcquisition Cost
Rolling Mill$750
Texture Plate$10
Shape Template$8
Fine Point Sharpie$3
Joyce Chen Shears$21
Flex Shaft$120
Flex Shaft Motor Hangar$32
Sandpaper Roll$1
Dapping Block$2
Nylon Hammer$14
Hole Punch$14
Liver of Sulfur$18
Mason Jar$2
Cup Warmer$11
Baking Soda$3
Container$2
Tumbler$110
Ceramic Media$45
Dawn Detergent$2
Extra Tumbler Barrel$36
Stainless Steel Shot$26
Burnishing Compound$10
Chain Nose Pliers$26
Paper Hole Punch$9
Total$1,275

Add that to the $55 in materials and you come up with $1,330. So if the only thing I ever made was those six pairs of earrings, their cost would be $222/pair.

Yes, that’s absurd. Of course I make more than six pairs of earrings with all this stuff. But how many pairs of earrings do I need to make and sell at $39/pair to cover my investment in tools and equipment?

Think about it.

Skills

And then there are skills, which come with training and experience.

I am not exaggerating when I say that I’ve spent thousands of dollars on jewelry making courses — in-person and online — as well as books and magazines. YouTube videos can only take you so far — what works best is one-on-one time with someone who has actually been doing this for a while.

And practice. How many times did I screw up a piece of metal in my rolling mill? Or cutting it apart? Or oxidizing it? (I’m still smarting from a bad oxidation job on 3 pairs of Keum-boo earrings where I used a new (to me) solution and darkened the gold as well as the silver. Ouch.) Or any of the other steps that went into this project? Practice really does make perfect — or as close to it as a person can get. Practice takes time and burns through materials and supplies. It’s no coincidence that we practice with copper instead of silver or — heaven forbid — gold.

Time

Time is easily quantified for this job since I know when I started and when I finished: 3 hours. That comes out to 30 minutes per pair of earrings. This is why I made stuff like this in batches; it’s a much more efficient use of time.

But how long did it take last time when I didn’t necessarily have everything as well organized? And how long will it take next time, when practice makes me a bit faster?

And shouldn’t I be compensated for my time? Clearly, I wasn’t compensated directly for the time I spent in training or reading up on new techniques or ruining materials because of inexperience or dumb errors. I should, at least, be compensated for the time I spent actually creating salable pieces of jewelry, no?

The Bottom Line

Finished Earrings
Some of the finished products.

Here’s the bottom line: I took 3 hours of my time and used thousands of dollars worth of training, hundreds of hours worth of practice time, and $1,330 worth of materials, tools, and equipment to make 6 pairs of earrings that I’ll sell for $39/pair.

I think buyers are getting quite a deal, don’t you?

Glue? In a Silversmithing Video?

I vent a little about people who should know better showing junk jewelry shortcuts in their jewelry-making videos.

I watch a lot of videos about making jewelry. I must have seen hundreds of them by now. Most were on YouTube, but I’ve also purchased in depth jewelry making videos on DVD or streaming services. I learn a lot from these and they can inspire me.

My favorite jewelry makers on YouTube

Want a few suggestions for getting started? Here are my top 5 favorite jewelry makers on YouTube:

  • Soham Harrison. Soham makes no-nonsense videos that really teach techniques. His camera setup isn’t fancy but it does the job. Lots of his videos are great projects for beginners, but there’s some advanced stuff, too. Soham is based in Australia but his accent is American.
  • Online Jewelry Academy. This one uses a set to record videos on a wide range of topics. The host, Professor John Ahr, is knowledgeable and a little weird. Lots of great videos for beginners here.
  • Andrew Berry. Andrew Berry is another jeweler who teaches jewelry making. His videos cover a wide range of topics. I believe he’s based in the UK.
  • Estona Metalsmithing. I recently discovered this channel and have watched quite a few of her videos. She seems to be making an effort to build up her subscriber base with quality tutorials. There’s a great beginner’s series and a bunch of other videos that go beyond the basic. She’s based in the Netherlands and speaks with a heavy accent, but her English is perfect. Just be aware that her terminology doesn’t always match the terms we use here.
  • Rio Grande. Rio is a jewelry making supplier and they’ve got a bunch of videos that teach techniques, many of which are related to items they sell. While some are strictly marketing videos, there’s lot of good how-to material, too.

Before I go any further, however, I need to warn wannabe jewelry makers that there are a lot of crap videos out there. Videos that show you how to make junk jewelry or videos made by people who obviously don’t know what they’re doing and make videos out of their experiments. I also occasionally have trouble with the personalities (or voices, even) of some of the video makers. I have zero tolerance for people who spend more time talking about how smart they are than actually showing you how to make something great. And that woman who talks like Cindy Lauper? Sorry. I just can’t keep tuning in. So although I encourage you to watch videos to learn, be prepared to wade through a lot of crap to find gold.

All that said, yesterday I watched a video from Durango Silver, which is a well-known turquoise and jewelry seller seller based in Durango, CO. The video covered making a basic gemstone pendant and although I’ve seen dozens of videos on that topic and have made many of my own, I checked it out, hoping to learn a few new tricks.

The guy who was making the piece — John — definitely had experience and knowledge. His narration was better than average, but far from perfect — for example, he occasionally used the wrong word for something or left sentences unfinished as he was working. It amazed me when he started talking about how much he loved a particular pair of pliers, pointing out that they were made in Pakistan (like 75% of jewelry making tools) and struggling to get the name Wubbers out with a laugh. Why did that amaze me? Well, Wubbers is generally recognized as a quality brand of tool and I really think he should have been familiar with the name.

The camera work was excellent. Most videos are one-person affairs where the camera sits on a tripod that may or may not be in the best position; this video had a camera guy who did a great job staying focused (literally and figuratively) on what we needed to see.

The video was long — 50+ minutes — and I watched it on my new bedroom TV setup. That means I fell asleep before he was done. (I cannot read or watch TV in a horizontal position without falling asleep.) In the morning, however, I finished watching it on my iPad while I had breakfast. I did learn something — a new (to me) technique for attaching a bail — and, because of this, I consider watching the video time well spent.

Stick Soldering
Screen capture from the video showing John soldering the bezel and a jump ring to the back plate. One of the things I learned in this video was a new (to me) technique for using a jump ring to connect a pendant bail. He also demonstrated stick soldering, which I’ve seen a few times but haven’t tried yet.

That is, until I got to the end. You see, John was creating a bezel setting for a cabochon. A bezel is a strip of thin metal — silver, in this case — that is formed to fit the stone and soldered onto a back plate. When all the soldering and polishing is done, the very last step is to fit the stone into the prepared bezel and use a variety of tools to bend the top edge of the metal down around the stone to hold it in place. This is a standard bezel setting technique. Look it up, take a class, watch a bunch of bezel set videos and 99% of them will show you this correct way.

The video started going off the rails for me when John reached for a coffee mug full of sawdust and put some into the bottom of the finished piece, under where the stone would go. Sawdust. A wood product. In a piece of sterling silver jewelry.

Sawdust in a Bezel
Here’s another screen grab from the video. This one shows the layer of sawdust at the bottom of the bezel.

He then put the stone on top of it. The sawdust’s job was to raise the stone a bit so the bezel wouldn’t come up too high on the stone.

Let me take a moment to explain how getting the bezel the right height for the stone is usually done. There are two techniques to choose from:

  • Before shaping and soldering the bezel, cut it to the right height. This is the correct way to do this. It’s a pain in the ass because you’re normally only trimming off a millimeter or two and it’s important to make a good, level cut. If your cut is bad, you can level it out with sandpaper after soldering it closed.
  • Put something under the stone to raise it. Folks who do this normally use some sort of material that will not decay in any way. Tiny cut up pieces of credit cards are popular. I have, in the past, used copper sheet cut to size. (I once made a pair of earrings with bezel set cabochons and although the stones matched in appearance, one was definitely thicker than the other; I used copper under the thinner one to make it match its mate.) I’ve never seen anyone use a biodegradable product like sawdust.

Okay. So this guy used sawdust. He called it “jeweler’s sawdust.” I’ve never seen it before — and I’ve shopped at a lot of jewelry supply sites and stores. Maybe that’s acceptable in the business? I didn’t know but I also wasn’t going to switch.

What he did next, however, floored me. He pulled out a bottle of liquid glue and, using the needle-tip applicator, glued the stone into the bezel.

Glue
He called that stuff “superglue.”

I screamed at my iPad: “Not glue! Don’t fuck it up with glue!

Of course, he kept gluing. I turned it off. I couldn’t bear to watch him permanently affix, with “superglue,” a beautiful cabochon to a very nice sterling silver setting and the sawdust beneath it with glue.

(I later watched the end. He did use a bezel setting tool to close up the bezel over the stone. But why the glue? Ugh.)

Later, I went back to look at the comments people had left on the video. Everyone loved it. Half of them said that they’d been wanting to try something like this and now they thought they were ready to do it.

I was horrified. He was teaching new jewelry makers a lazy way to do a bezel setting. A way that allowed makers to rely on glue instead of design and skills to set the stone.

But what was worse was that he was showing me that the jewelry made and sold by Durango Silver is likely held together with glue rather than the skill of the jewelry artist.

I guess the moral of the story is this: don’t just watch one video about how to do something. Watch a bunch. Pay attention to the details. If there’s a technique that most of the video makers are using, maybe it’s the right technique.

With very few exceptions, glue has no place in fine jewelry.

B&S Gauge Thicknesses, Saw Blades, and Drill Bits

Another handy chart for jewelry makers.

The other day, I published a chart of Minimum Metal Gauges for making jewelry. I’d made the chart for my own use, based on information I got from the Rio Grande website.

But what I’ve really wanted for a long while was a single chart that listed B&S gauge sizes, the corresponding measurements in millimeters and inches, and the correct jeweler’s saw blade and drill bit sizes for each gauge. For some reason, I could not find all of this information on one chart anywhere.

So I made one by combining information from the Contenti and Livingston Jewelers websites. Here’s the result:

Thicknesses, blades, and bits
This is the chart I’ve been looking for! In the end, I had to make it myself from multiple sources of information.

You can download this chart as a PDF from my public Dropbox folder.

Keep in mind that although I do have a set of jeweler’s drill bits, I don’t use them. Instead, I have a set of bits in various fractional mm sizes — I pick the drill bit I need from that set because I can get a much closer drill bit size for my needs.

Minimum Metal Gauges

A handy chart for choosing metals for jewelry making.

My “day job” may be flying helicopters, but I moonlight as a jewelry artist. I’m constantly looking for reference materials to help me choose the right tools and materials for making jewelry. I find charts extremely handy since I can print them out and attach them to a wall beside my jewelry making bench in my shop. No need to rely on my memory since the chart is right there.

I stumbled upon one on the Rio Grande website recently. It was almost what I needed. I modified it to add information I needed and remove metals I don’t work with. (I only work with sterling, Argentium, and Fine silver and copper.) Here’s the result:

Recommended Metal Gauges
Table of metal gauges. “NR” means not recommended.

You can download a copy in PDF format from my public Dropbox.

If you find posts about jewelry making interesting, please take a moment to leave a comment and let me know. Thanks!

Adding Power to My Utility Trailer

I splurge on batteries and an inverter for my utility trailer/mobile jewelry shop.

For the past five winters, I’ve been traveling south in my truck with a slide in truck camper on the back. It started with “the Turtleback” in 2016/17. That was a very large and rather deluxe Lance model with all the bells and whistles, including an onboard generator and a slide-out to expand living space when parked. Then I downgraded to a smaller, newer rig, “T2,” which was roughly the same length, not quite as deluxe, and lacked both the slide and generator. What I gained in the swap was a 400-pound weight loss and a lot more inside storage space.

Why a Utility Trailer?

Over time, however, I started bringing more additional items south than I could fit inside the camper or truck. Normally, I’d have my portable Honda generator in the truck, along with my bicycle and wrangle my plastic kayak onto the roof of the camper. In 2017, I brought my little jet boat south with me and loaded it up with extras, including that kayak, for the trip south. It was nice to be able to store extra stuff in a trailer.

In 2018, on my way to my first camp, I stopped in Lake Havasu and bought an inflatable Hobie pedal/paddle kayak. Sure, the 11-foot boat deflated and fit into a bag with wheels, but that bag was both bulky and heavy. I shoved it into the entranceway of my camper for the rest of the drive to camp, but quickly realized that dealing with it in transit was going to be a royal pain in the ass.

My Rig
Here’s my truck, camper, and original utility trailer not long after I bought it. Note the dent in the upper corner.

So I got on Craig’s list and bought a 12-foot cargo trailer. It was a bit “rough,” as I blogged not long after acquiring it. I hooked that up to the back of my rig and stowed all the extras I’d crammed into my truck and camper. It had two axles, but I had trouble getting the tow ball height just right to distribute weight evenly on both of them. It was also a bit rickety and had me worried about long distance driving with it. But it made it back to Washington intact. I wasted no time selling it to a friend who was looking for a tool trailer that could be parked on job sites.

Truck and Trailer
Here’s my current rig. The newer trailer is in much better condition than the original one and includes a toolbox on the tow hitch.

I went hunting for a new one. Literally new. My search brought me down to Yakima, where I stopped in at the Lance dealer for a part I needed for my camper. I mentioned that I was going to look at some utility trailers at a dealer down the road. Mike, the co-owner, mentioned offhand that he and his partner brother had a utility trailer that they never used and would consider selling. I took a look. It was almost exactly what I wanted. I looked at the new ones, then called Mike back and started negotiating for his. About a month later, at the tail end of a trip to Tacoma, I picked it up.

I started customizing the interior almost immediately, adding E-track to the walls so I could secure various items to it. The goal was to turn it into a sort of mobile jewelry shop that could also haul the things I needed to do jewelry shows and camp. I loaded it up and secured everything, but wasn’t very happy about its setup as a shop — I had to take out too many things and set up a workstation on folding tables and then be sure to stow everything before moving. Boxes were big and piled up and difficult to access. The IKEA drawer units I’d put in had limited storage space for the weight they added to the rig. It was uncomfortable and inconvenient and it just didn’t work out the way I’d imagined it would.

So this year I built the tables and shelves I needed to make a real shop area in the front of the trailer, leaving the back wide open for show equipment and camping stuff.


Here’s a brief video I shot the other day that shows off my mobile studio space while I’m parked. It also includes a glimpse of my new inverter. And did you know that I maintain a YouTube channel for ML Jewelry Designs? Find it here.

My Power Needs

Before I discuss my needs, I need to make it clear that I camp off-the-grid. I’m usually not in a campground, but if I am, that campground usually does not have any utilities running to the site. That means I need to be self-sufficient with power (as well as water and sewer). I rely primarily on solar power but also travel with a 2kw Honda generator, just in case I have cloudy weather or unusually high power needs in my camper.

What I’m discussing here is my jewelry-making power needs.

My primary jewelry-making tool is a flex-shaft. The popular brand name is Foredom and that has become a bit of a generic term for that kind of tool, but mine is a Eurotool brand. It’s basically a hanging drill motor attached with a flexible shaft to a hand piece that can accept Dremel sized tools. You turn it on and off with a foot pedal that controls the speed of the motor. Because this tool requires AC power and the only way I can get continuous AC power while camping off the grid is to run my generator (which I don’t like running because of the noise), I didn’t bring it. Instead, I brought my battery operated Dremel, with its spare battery and charger.

I also use a small rotary tumbler quite a bit, as I discuss in this blog post. That also requires AC power, but it only needs 36 watts. Unfortunately, sometimes I need to run it for hours at a time. I was able to run it with a portable 150 watt inverter attached to the power port in my truck or in a battery pack I’d bought primarily to run my telescope. I quickly ran down the battery pack and had trouble getting it charged back up. And the idea of draining my truck batteries to run a tumbler was not very pleasing.

I also found myself with lots of other little batteries that needed charging. My camper does not have an inverter; due to limited space, it only has two 12v batteries. (Higher capacity 6v batteries will not fit in the storage cabinet — I’ve already looked into it.) On short winter days with a low sun angle, the 200 watts of solar flat-mounted on the roof can basically keep those batteries charged and let me use DC power ports to charge my phone, watch, and iPad but not much more.

The Solution

Last year, I’d looked into getting a solar charged battery power system installed into the cargo trailer. The trailer has a metal toolbox on the hitch bars and I figured it would make a good place to put the batteries. I already had a Zamp portable solar panel that I could attach to my camper. Why not use that to power a 2kw system on the utility trailer? But the estimate I’d gotten — more than $3,000! — gave me pause. A whole year’s worth of pause

This year I went forward with a less ambitious setup that included just two 6v batteries and a 1kw inverter. I had it installed in Quartzsite, AZ, where there are numerous solar power dealers who work on RVs. (I went to Solar Bill’s, but Discount Solar is another dealer there.) It still wound up costing about $1200. But if I kept the batteries charged, I would have all the power I needed to run my tumbler and charge just about any device that needed charging.

Solar Panels PM
Here are my solar panels in my current setup location. The original location had the panels in full sun from around 9 AM to 5 PM; in this new spot, they get sun at 8 AM but start falling into shade around 3:30 PM. The cable for the panels is only 12 feet long and the plug for it is at the front of the trailer. Poor parking planning on my part, but it’s all good.

Plug and Outlet for Solar Panels
Here’s where the panels plug into the side of the toolbox where the batteries are.

Batteries for Solar Setup
Here are the batteries inside the toolbox. There’s a vent hole behind them. I lost about half the box capacity to store things; I can’t put anything on top of them.

1000 Watt Inverter
Here’s the inverter, mounted in the front corner of my trailer just under one of the shelves. I’ll likely use the area around it as a charging station for various batteries in the future.

I brought it all back to camp, set up the solar panel in a good spot, and let the system do its thing. It was a bit iffy at first. Although the batteries were charged when I got them, I don’t think they were at 100%. My immediate use brought their power levels down a lot more than I expected. But after a few days with bright sun on those panels — including days when I didn’t use the power in the trailer at all — I soon had the batteries fully charged and able to share that power with any device I plugged in without a considerable power droop. I even managed to charge that big battery pack overnight without draining the system batteries.

I’ve since set up a little portable table near the inverter where I’ve parked various battery chargers — for my Dremel, my Ryobi tools/lights, my drone, and even my laptop. It has become the go-to place for charging things and it does a remarkable job. In the future, I’ll probably just use the shelf beside the inverter to set up a charging station.

Since moving my cargo trailer closer to my camper, I’ve also moved those portable panels closer. That means that if the utility trailer batteries are charged up and I don’t need them, I can attach another 160 watts of solar to my camper to bring those batteries up to full.

And yes, I did look into putting 200 watts of solar on the utility trailer’s roof. It would have cost me an extra $1400 for the panels, controller (which is built-into my portable panels), wiring, and labor. Not worth it — at least not yet.

Long Term Benefits

I know I won’t be traveling like this every winter forever. In fact, I’m starting to think the this might be my last year at Arizona’s Colorado River backwaters, where I’ve been coming since 2014. I’m starting to feel as if I’m stuck in a rut and and after living too many years in someone else’s rut, there’s nothing I hate more than that.

I’ve been thinking of making some major changes in my life that includes shifting focus on how I spend my free time. There will come a point when I don’t need that utility trailer at all. It seems a shame when I’ve spent so much time and money customizing it.

But the way I see it, the improvements I’ve made to the trailer make it even more flexible for me or a future owner. I can see converting it into a small living space for rugged camping — there are quite a few people camping in converted utility trailers out here in the desert. My jewelry workbench illustrates how easy it is to build removable structures onto the E-Track I’ve installed. Where I’ve put in a workbench, someone else could easily make a platform for a cot or other sleeping space. The storage shelves in the nose of the camper aren’t pretty, but they do make it possible to store lots of things in a way that can be easily secured in transit. And the power makes it even more attractive for off-the-grid use. All it takes is a need and a little imagination.

Until then, I’m enjoying the upgrade.