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4-Star Construction

4 Star Trailer Logo

The 2006 model year 4-Star trailer introduces the 4th generation Concept II slat. The unique design of the 4-Star Concept II slat eliminates weld melt-through and 90% of visible heat distortion. Concept II slats solve the problem of leakage in the stacking of slats by using a water resistant interlocking joint that also significantly increases the strength of the slat compared to corrugated slat designs. It also minimizes and reduces the number of voids between the slat and the trailer side posts thereby contributing to an even more water resistant slat than was previously obtainable. Concept II slats are installed along the full length of our trailers contributing to 4-Star Trailers’ legendary beauty, strength, and durability.

Top and Bottom Rails:
4-Star Trailers is recognized for building one of the most, if not THE most, durable trailer in the industry. A major factor contributing to the overall strength of a trailer is its top and bottom rails. Our rails were designed borrowing design features from semi trailers with GVWR’s of 60,000 lbs. Every 4-Star trailer uses the same top and bottom rail regardless of trailer length. The only differences are the inclusion of running boards for trailers 8’-0” or less in width. The bottom and top rails used on a 16’ long bumper pull trailer are same as those designed for use on 53’-0” long trailers. We use them across all models so that each 4-Star Trailer shares common looks with its siblings. Our top rail is a hollow, full length, heavy wall, extruded tempered aluminum structural strength beam. The hollow tube design of our top rail is the only one of its kind that we know of in the industry. In addition to the strength inherent in its hollow tube design, the large 6 inch radius on the outer wall resists twisting and warping under stress. The hollow shape also creates the perfect conduit for protecting the electrical wires running through it. The hollow shape makes it more difficult for us to run our light and accessory wires, but we feel that the additional strength conferred to the trailer make it worth the extra effort. Our bottom rail is one of only a few in the market to extrude the running board and bottom rail together as a single piece. Others continue to weld running boards to their bottom rails. Our integrated design adds stiffness to this important structural member while minimizing the number of welds visible on the bottom rail.

Side Wall Construction:
Our side posts are hollow rectangular tubes, extruded in three sizes, 1” x 2 1/2”, 1” x 4” and 1” x 8” with 1/8” minimum wall thicknesses. Even though it is more expensive to extrude a hollow tube, as opposed to an open shape like a C-channel, we feel that the extra strength imparted to the side wall makes it worth the investment. To minimize sharp edges, the side of the post facing the inside of the trailer is rounded with 1/2” radius corners. Three sides of the post have heavier (9/64”) walls to provide resistance to heat distortion when the slats are welded to it. Each size is suited to the purpose for which it was designed. Door frames, ramp openings, windows, etc., each requires a post designed for that function. Due to the highly customized nature of our business model, our customers often ask us to do things that change the structural dynamics of the side wall of the trailer. Using sophisticated CAD structural analysis tools, we developed effective methods to insure that special requirements do not cause problems. As an example, when circumstances require it, we use a specially engineered aluminum reinforcement developed by 4-Star and validated by one of the nations leading aerospace consultants. The reinforcement is judiciously located and attached to our bottom rail in high stress areas to effectively neutralize concentrations of stress by dissipating it throughout its length. All our Deluxe model horse trailers are double walled and insulated in the horse compartment. The kick walls are lined with.090 aluminum and the head wall with.063 aluminum. Rubber is bonded to both the head and kick wall. We are the only manufacturer we know of offering a lifetime warranty on our wall rubber.