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Camping - Caravanning - Camper Trailering - Four Wheel Driving - Off Road - Fishing >> DIY Caravan & Camping Tips & Tricks >> jclures DIY crossover camper
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Message started by jclures on Mar 31st, 2016 at 10:23pm

Title: jclures DIY crossover camper
Post by jclures on Mar 31st, 2016 at 10:23pm
I was asked by a member if I will post up my building my new camper on the forum, so I post it up as I go, mind you it may take awhile for me to finish it.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Trailer%20frame%20jig%2002_zpszqetxuug.jpg

The shed was cleared out and I built the stand to build the chassis. Now I have started to put what I have planed into the real world.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Starterd%20the%20new%20camper%2001_zpsy8rn0nos.jpg

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 31st, 2016 at 10:24pm
I have now cut all the A frame steel and have started capping and cutting the angles needed in the chassis design.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20Camper%20drawings/not%20to%20long%20chassis%20front_zpssu3an6sx.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/New%20Chassis%2002_zpsguhsxrq5.jpg

Leaving the steel under the trees has left a stain from the sap, I hope to clean each section as I go before welding.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/New%20Chassis%2001_zpsszb9ugju.jpg

I will cut all the steel to plan at 90deg then re cut the angles, so far the measurements are with in 2mm, I think the discrepancies are due to the angle cut on inside or as plan outside measurements

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 2nd, 2016 at 9:12pm
I am hoping to save weight where I can, hopefully without taking away the strength in the chassis.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/New%20Chassis%2003_zpsewsxsgvt.jpg

I also am trying to allow for wiring to run through the chassis, so I am cutting holes to run a pull through wire as I build it.

Once all the cutting is done tack then weld the two pieces together for the right A frame rail.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/New%20Chassis%2004_zpsfit0yswu.jpg

how to work on the other side rail.

Title: Re: jclures DIY crossover camper
Post by Derek on Apr 2nd, 2016 at 9:20pm
I am fascinated by all this John.  Thanks for sharing.  Looking forward to seeing it all come to life.

Title: Re: jclures DIY crossover camper
Post by shackles on Apr 2nd, 2016 at 9:54pm
How long do you think it will take to build John?

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 2nd, 2016 at 10:04pm
I don't have a set time, but I work only my shoulder is not giving me trouble, so I would be just guessing if I said this time next year.

Title: Re: jclures DIY crossover camper
Post by TBF on Apr 3rd, 2016 at 7:16am
Thanks for the report John.. I shall be following your progress with much interest.

Aart

Title: Re: jclures DIY crossover camper
Post by paulhenry on Apr 3rd, 2016 at 8:04am
This will certainly be an interesting project to watch. Keep the posts coming.  I'm guessing it's your first time using a grinder and welder. I'd be happy if I could make the frame you made to start the job on. Top work.

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 3rd, 2016 at 10:54am

paulhenry wrote on Apr 3rd, 2016 at 8:04am:
This will certainly be an interesting project to watch. Keep the posts coming.  I'm guessing it's your first time using a grinder and welder. I'd be happy if I could make the frame you made to start the job on. Top work.

No this is not my first foray into home building or modifying, but I still am learning though.
Here are a couple of links into some of my other jobs.

http://www.myswag.org/index.php?topic=1493.0

or

http://www.4wdaction.com.au/forum/viewtopic.php?f=22&t=17736


Title: Re: jclures DIY crossover camper
Post by paulhenry on Apr 3rd, 2016 at 3:47pm
Wow. I love the camper trailer.  I'd read about the nisota somewhere else before. Keep up the good work.

Title: Re: jclures DIY crossover camper
Post by Chally on Apr 3rd, 2016 at 8:00pm
Enjoying seeing the build.

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 10th, 2016 at 9:45am
I have finished the two a frame sections, and welded the front brace. I will fit the plate for the hitch later on.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/pull%20through%20wirers_zpswgiulc9z.jpg

I have run the pull through wires through the front brace, trailer lighting down one side and 12v power to charge the batteries, down the other. There is also allowance for the brake wiring as well.

I am now working on the front main chassis rails. Once again I am trying to minimise weight where I can, I have cut the sections to still give cross brace support and the two pieces don't have the holes in the same area.


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/left%20chassis%20rail%20ready%20to%20assemble_zpsuhlqne4z.jpg

I hope I can get this welded today and fitted to the chassis.

Title: Re: jclures DIY crossover camper
Post by Chally on Apr 10th, 2016 at 6:44pm
Good seeing the progress.

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 10th, 2016 at 9:07pm
I have finished welding the rails together, and I now can put them together to the a frame. Once in place and checked for square and tacked ready to weld.


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/A%20frame%20and%20chassis%20ready%2001_zpsg70xhl07.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/A%20frame%20and%20chassis%20ready%2002_zpsapjzbcmp.jpg

I am using gas less wire so I am trying this product, I think it makes it easier to clean up after welding, just a quick brush with a wire brush and  no grinding.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/wurex%2001_zpsgmbh9qgs.jpg

The front chassis is now together.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/A%20frame%20and%20chassis%20finished%2001_zpsxn75cu2k.jpg

I just need the cross braces finished, which I have started.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/cross%20rails%20started%2001_zpskgol1ceb.jpg

And then the frame for the front storage compartment to be fitted.
Also the supports for the water tanks as well need to be fitted.

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 10th, 2016 at 9:08pm
It is slow progress I can tell you Jeff.

Title: Re: jclures DIY crossover camper
Post by Chally on Apr 10th, 2016 at 9:15pm
It certainly is but it will be all worth it when finished.

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 11th, 2016 at 8:13pm
I am planing on fitting two water tanks under the camper, but I am allowing for a third if needed. This has led to my first mistake , some how in the planing in measured the tanks 15mm narrower so two tanks make 30mm.  I found my mistake once I tried to fit them in place.
Luckily I had only welded one of the cross braces so I removed it and moved it the 30mm forward.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/front%20water%20tanks%2001_zpsjexkifba.jpg

The extra front tank might never be fitted, but better it get it right now, so if I want I can just bolt the extra tank up.

Title: Re: jclures DIY crossover camper
Post by TBF on Apr 11th, 2016 at 10:24pm
How big are the tanks John?

Aart

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 11th, 2016 at 10:28pm
80 litre tanks from Dunn & Watson.

Title: Re: jclures DIY crossover camper
Post by Rolly66 on Apr 12th, 2016 at 4:46pm
Jc you are doing an amazing job looking forward to seeing your progress

Title: Re: jclures DIY crossover camper
Post by TBF on Apr 12th, 2016 at 8:33pm

jclures wrote on Apr 11th, 2016 at 10:28pm:
80 litre tanks from Dunn & Watson.


That's plenty for a week or two..
Aart

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 12th, 2016 at 8:50pm
That is what I think as well, but they tell me I might need to bring my grey water back in some national parks, so I am future proofing the design. 

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 14th, 2016 at 9:04pm
I had a couple of corners in the chassis design I could not get to to weld them up, so my solution was a gusset, rightly or wrongly I have done it this way, and I am happy with how they have come up.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/chassis%20gusset%2001_zpspf5p5msh.jpg

The next bit to get done is the front plate for the hitch, I centre lined the the plate and put a permanent pointer so I can check alinement’s. I also need the hitch fitted as a pivot so I can turn the chassis over to finish of the welding.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/treg%20fitted%2001_zps8zr0b76o.jpg

I think I will gusset the plate as well, the holes are for the two hammer locks to hold on the safety chains.

Title: Re: jclures DIY crossover camper
Post by Derek on Apr 14th, 2016 at 9:05pm
Looking very neat John.

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 18th, 2016 at 8:14pm
Thanks Derek, I have a saying, I might not be quick but I am rough enough. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 18th, 2016 at 8:18pm
Over the weekend I was able to get the front of the chassis rotated, I used my engine crane (my left Arm) on one end and the over head winch on the other. I welded a temporary pivot point for the winch to give me a safe point to turn it over. Once over I finished most of the welding and  started to clean the steel with a wax and grease remover and prim with a gal primer.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Chassis%20front%20finished%2001_zps1oqa22g2.jpg

I then started on the rear section of the chassis. This is not as hard to build as the front section in some ways but I need to get it so the chassis rails line up with the front section.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Chassis%20rear%20started%2002_zps1nvolfo8.jpg

It also has the what I would call the duck tail built in as well. This is something I am thinking about  now should I weld or bolt on the bumper on the chassis. I am thinking bolt on will be the best way for me.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Chassis%20rear%20started%2001_zpscdkwhaqb.jpg

Title: Re: jclures DIY crossover camper
Post by Derek on Apr 19th, 2016 at 9:45am
It actually looks much bigger than the dimensions in one of your previous posts.

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 19th, 2016 at 10:52am
Derek this should give you an idea of the finished chassis. 5.550m long excluding hitch and bumperbar and 1.950m wide.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20Camper%20drawings/not%20to%20long%20shorter%20chassis_zpspjknwefm.jpg

It is a pretty big project for me, I have put a lot of thought on how I can build it, and I don't think there is anything on the market like I am building. My roof if it goes as planed will hinge from the back, end and it will have folding walls, with no canvas.

Title: Re: jclures DIY crossover camper
Post by Rufzgutz on Apr 19th, 2016 at 10:56am
Very, very impressive jc.

Enjoying watching your journey.

Title: Re: jclures DIY crossover camper
Post by shackles on Apr 19th, 2016 at 1:54pm
Coming along nicely JC. We hope to see you in about 4 weeks time. Do you think you will have it finished by then?  ;D ;D

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 19th, 2016 at 2:07pm
No trouble. ;) :)

Title: Re: jclures DIY crossover camper
Post by Chally on Apr 19th, 2016 at 4:07pm
Very interesting seeing it taking shape John.

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 19th, 2016 at 8:44pm
Jeff I am enjoying it taking shape too. :) :)

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 19th, 2016 at 9:01pm
I have been collecting some of the parts for this build for some time.

Speedy Wheels 16 x 8”  28mm offset.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20trailor%20wheel%2001_zpso02yzni6.jpg

Air Bags

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Air%20Bags%2001_zpstvgcsf1n.jpg

actuators

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/600mm%20lift%20500Kg%20%20acuators%2001_zpsjgfpkuad.jpg

12” heavy duty brakes, Land Cruiser wheel bearings.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/2T%20Brakes%20Parts%2001_zpsws98hwk8.jpg

I have a few other goodies to fit as I go as well.

Title: Re: jclures DIY crossover camper
Post by Derek on Apr 19th, 2016 at 9:05pm
.
thumb_001.jpg (18 KB | )

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 21st, 2016 at 9:14pm
I am having a couple of beers tonight, I have hit a important mile stone. I have attached the chassis two ends together and so far with no distortion, very happy.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/first%20arches%20in%20place%2001_zpsk9akderf.jpg

I have also finished the rear end of the chassis.


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/first%20arches%20in%20place%2002_zpssd5oo4gh.jpg

I will take time to finish the welding of the arches in place so not to generate to much heat, trying not to get any distortion in the chassis.

I can then start on the two inner arches to finish the chassis frame, ready then to work on the suspension and axle.


Title: Re: jclures DIY crossover camper
Post by Chally on Apr 21st, 2016 at 9:37pm

jclures wrote on Apr 21st, 2016 at 9:14pm:
I am having a couple of beers tonight,


Well enjoy them mate as it looks like you have definitely earned them. :)

Jeff

Title: Re: jclures DIY crossover camper
Post by Rolly66 on Apr 22nd, 2016 at 8:20am
Seems like it's coming along nicely jc bloody amazing job your doing

Title: Re: jclures DIY crossover camper
Post by mikel on Apr 23rd, 2016 at 6:51pm
Looks good, going to be very robust I would say.
Just one question... when did Land cruiser's have tapered axles, different diameter bearings.
What you show could be a weak link in your design?
mikel

Title: Re: jclures DIY crossover camper
Post by jclures on May 2nd, 2016 at 12:27pm
I thought al the Toyota  series 70 to 105 run this kit, (1975 through to 2013) excluding the IFS models. The inner is a large bearing, much larger then the parallel bearings I am running on my current camper.

Title: Re: jclures DIY crossover camper
Post by jclures on May 2nd, 2016 at 1:58pm
This should give you some idea, the bearings on the left are a heavy duty parallel, and the bearings on the right are what I am using.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/bearing%20size_zpslz6kupoq.jpg

Title: Re: jclures DIY crossover camper
Post by jclures on May 2nd, 2016 at 8:18pm
I was able to get my inner arches fitted the day I went into hospital, I have a bit to finish of then I can turn the chassis over and start fitting the axle.
Once I am allowed down the shed again, that is. ::)

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/inner%20archers%20fitted%2001_zps6h0cqpbz.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/inner%20archers%20fitted%2002_zpshwzqwux4.jpg

I am now working on the weights off plan, and doing some maths to see how close my estimates are to the true ball weight at this stage of the build.

Title: Re: jclures DIY crossover camper
Post by Rolly66 on May 2nd, 2016 at 10:51pm
Take it easy jc it'll still be there when your ready
Fantastic sometimes takes a little longer
We got time mate

Title: Re: jclures DIY crossover camper
Post by jclures on May 12th, 2016 at 9:57am
I have weighed the A frame Putting a pivot where the axle will be, to check on my estimates. I estimated of plan a weight of 65kg, but the weight really is 58kg, I am pleased I am on the lighter side of my estimates.

I have now started building the axle, I plan on the wheels being at 0 deg camber and toe. Although some reading suggests I could do otherwise.

I have centered the stubs into the 65mm box steel and I am adjusting the settings using the bolts.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/new%20axle%2001_zpssonj2ryr.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/new%20axle%2002_zpsmkj4vnmh.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/new%20axle%2003_zps99ffjxq2.jpg

Once centered I will weld them in, also plug welding the ends of the stubs as well.

Title: Re: jclures DIY crossover camper
Post by Chally on May 12th, 2016 at 12:31pm
Very interesting to see all this being done.

Jeff

Title: Re: jclures DIY crossover camper
Post by GROMET on May 12th, 2016 at 10:41pm
Looking good so far 

Title: Re: jclures DIY crossover camper
Post by jclures on May 16th, 2016 at 7:47am
On reflection I decided not to centre the axle I ended up making it with 1mm toe in an I planed on 1mm positive camber. Once the axle cooled I checked these measurements and I had lost .5 mm camber on one side. So one side is zero camber now and there is nothing I can do about it,  so that is the way it will stay.

The next bit to work on is the air bag mounts, I made and tacked in place the top mount, then made a dummy mount to represent the air bag fully compressed.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/top%20airbag%20mount%20tacked_zpsy3ddwrf5.jpg

With this in place I them placed the axle in place making sure it is in line and centre them tacked on the axle air bag mount.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/axle%20airbag%20mount%20tacked_zpsywtnz4an.jpg


Now it is ready for me to start to fit the arms in place.

Title: Re: jclures DIY crossover camper
Post by jclures on May 16th, 2016 at 8:47pm
This arrived in todays mail, I had thought about another tank but this one was a good price I thought.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20camper%20parts/Air%20Tank%201_zpsbzavnpda.jpg

I think I will need to cut the brackets to fit, but this should fit nicely between the chassis rails.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20camper%20parts/Air%20Tank%202_zpsungtfbet.jpg

Title: Re: jclures DIY crossover camper
Post by jclures on May 18th, 2016 at 9:41pm
I have now started fitting the trailing arms to the axle. The top arms are the hardest to get right, as I an trying to get the axle when it travels from ride hight to bump stop to be in line so the air bag is compress square to the mounting plates as well as being square at ride hight.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Top%20trailing%20arm%20fitted%2001_zpsqzcyqkbx.jpg

Once I fit the bottom trailing arms I will know if my drawing are right regarding the air bag fitment.

Title: Re: jclures DIY crossover camper
Post by Derek on May 19th, 2016 at 8:20am
It is fascinating seeing this all come together

Title: Re: jclures DIY crossover camper
Post by Rufzgutz on May 19th, 2016 at 10:53pm
Love your input here jc with the updates.

I'm not that mechanically inclined, so like others, don't add many comments.

But, thoroughly enjoy your build  [smiley=clap.gif] [smiley=clap.gif]

Title: Re: jclures DIY crossover camper
Post by GROMET on May 20th, 2016 at 6:23am
Wow thats one big air tank for two bags
how are you planning to fill and maintain pressure in it

Title: Re: jclures DIY crossover camper
Post by jclures on May 20th, 2016 at 8:44pm
9 ltr tank it cost $90 delivered, I did look at the smaller tank but I thought this one is about right for me.
The compressor is still to be decided, I have a couple of Toyota compressors they fit to vehicles, with air ride suspension, so with a little modification these might work.
I put a pressure gauge on one today to see what pressure the pumps will pump to and it tested past 140psi,  how many cfm I won't know until I time the tank being brought to full pressure,  which I hope to over the weekend.

Title: Re: jclures DIY crossover camper
Post by GROMET on May 21st, 2016 at 7:50am
It looks a lot bigger than that
I have a 10 ltr in my ute for  tyre inflation and use an ARB pressure switch and a one way valve between the compresser and tank the has an on off preset of 70psi to 100psi 

Title: Re: jclures DIY crossover camper
Post by jclures on May 21st, 2016 at 9:58am
The photo does make it look big I guess.  If these Toyota compressors work it will save me buying a new one, and I have three of these.  There is nothing stopping me fitting two to speed up the pumping as well, a bit like the double pump ARB make.

Title: Re: jclures DIY crossover camper
Post by GROMET on May 21st, 2016 at 11:15am
What type of height control valve are you planding on using?

Title: Re: jclures DIY crossover camper
Post by jclures on May 21st, 2016 at 3:17pm
I am thinking something like this.

http://www.ebay.com.au/itm/Pressure-gauge-220S50-ride-suspension-twin-bag-control-unit-firestone-air-bag-/111936529787?&_trksid=p2056016.l4276

Title: Re: jclures DIY crossover camper
Post by jclures on May 24th, 2016 at 7:25am
I thought I should test the compressor filling the tank, it took around 5 minutes, so it was not fast but I think it should be adequate, as it pumped to 120psi no trouble and the compressor never got to hot, pumping for that time.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Testing%20Toyota%20Compressor_zpsbn78pvbt.jpg

I have now been told by the boss I can do a little work on the chassis again, so over the weekend I tacked the remaining trailing arm mounts in place. Once done I temporarily fitted the air bags to check the alignment.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Air%20Bags%20first%20fit%2002_zpsfrawhmca.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Air%20Bags%20first%20fit%2001_zpscedya9pr.jpg

I can now finish welding the brackets on and think about fitting the shock absorbers.

Title: Re: jclures DIY crossover camper
Post by GROMET on May 24th, 2016 at 9:41am
Just a question on the mounting of the bags
is the plate going to be strong enough to handle all the constant pounding and flex and not bend?

I am only going on how all our semi trailer air suspension is set up
also are you fitting shockers?

Title: Re: jclures DIY crossover camper
Post by jclures on May 25th, 2016 at 6:34am
Everything is just tacked in place, there will be supporting brackets on the airbag mount on the axle. Although the airbag also is sitting on the axle as well so it should be good when finished.

I hope to get back onto it today, going to the doctor to get a check up, then I should be able to start mounting the shock absorbers in place, if he lets me that is.

Title: Re: jclures DIY crossover camper
Post by jclures on May 29th, 2016 at 9:33pm
Fitting the shock absorbers I thought the best way was to make a dummy shock absorber. I made it eye to eye 10mm longer than the compressed length, this should allow for any top out in the suspension. The top bracket, (bottom in the photos) is mounted between the arches. It will be gusseted to the airbag plate to support it when finished.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Fitting%20shocks%2001_zpsjhjawcde.jpg

The bottom bracket ties the outer control arm brackets as well, when finished,

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Fitting%20shocks%2002_zpsv8r2qqvk.jpg

The bolts are 20mm, and I made then so the thread ends before the rubbers, with washers they should be strong enough and hopefully work as planed.

I still need to fit rebound rubbers and the panhard rod and weld in the gussets to finish the suspension.

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 6th, 2016 at 8:02am
I planed to have to bump stops on the outside of the chassis slightly to give clearance for the air bag when fully compressed. I first thought I might just make a mount, but I decided to use a piece of 50mm RHS, joggled in to fit.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/bump%20stop%20fitted%2001_zpsaizojkuq.jpg

The panhard rod I had to decide the best option for me, I ended up using a rod from the Holden Commodore. I have a couple of these spare, and I can also buy a adjustable unite for not a lot of money on Ebay.

I had to make a post for it of the chassis, but I wanted it to be behind the suspension pick ups, and it needed to try to get the arm as flat as possible to keep the ark of the arm minimal movement.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/panhard%20rod%20fitted%2002_zpsgg2fxaaw.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/panhard%20rod%20fitted%2003_zpskomerk9m.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/panhard%20rod%20fitted%2001_zpszyibbujg.jpg

with the suspension fully compressed the panhard rod is totally protected by the axle and suspension arms.

I can now start to finish of the welding, on the suspension, and the think about the hand brake cabling.

Title: Re: jclures DIY crossover camper
Post by Chally on Jun 6th, 2016 at 10:47am
There is so much detail that goes into a build like this; not something I could take on. John what are the dots along the cross member in the last photo; holes? It is hard to tell in the photo.

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 6th, 2016 at 10:52am
Jeff they are 6mm rivnuts in the cross member to hold the water tanks.

Title: Re: jclures DIY crossover camper
Post by Derek on Jun 6th, 2016 at 12:42pm
You can see why caravan manufacturers stick to the same chassis setup for lots of different models.

Just amazing seeing all this go together.

Title: Re: jclures DIY crossover camper
Post by Chally on Jun 6th, 2016 at 2:24pm

jclures wrote on Jun 6th, 2016 at 10:52am:
Jeff they are 6mm rivnuts in the cross member to hold the water tanks.


Thanks mate. I had to do a search to find out what they were. I could see them being very useful for all sorts of jobs.

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 6th, 2016 at 2:54pm
I have found you need good tools to set them in place, and I a now using a Australian made to which works well.
http://www.ebay.com.au/itm/M6-M10-Kit-Blind-Rivet-Nut-Nutsert-Rivnut-Insertion-Tool-/251677710608?hash=item3a99291910

Derek even though I have worked on the design for over 12mts I still am finding the odd thing I need to think about as I build it,. The park brake is an example, with the amount of travel I will have in the suspension a standard caravan cable system will not work, so I now have to work out how to fix this.

Title: Re: jclures DIY crossover camper
Post by GROMET on Jun 6th, 2016 at 7:40pm
Jeff just a sugestion on the brake cable
Would it work if you were to have a single cable from the brake handel to the centre of the axle and then a cable from both sides to that centre cable  sot of like a Y shape ?

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 6th, 2016 at 9:10pm
Gromet the problem is when the axle goes from ride hight to bumpstop, the ark reduces, which in turn would actuate the brake leaver on the brake drum. This is why cars use a encased cable so the fixed points don't do this.
Finding the right cable is what I need, I brought a set of cables for a VX Commodore today they look like what I need for the rear part of the system. The front half was easy.
John.

Title: Re: jclures DIY crossover camper
Post by jclures on Jul 22nd, 2016 at 8:26pm
I think I have finished the chassis. I have plated the areas I was worried about, and also changed a couple of things I was not happy with. I also have now allowed for the floor joints with a bit of work.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Chassis%20finished%2001_zpskh30tdgw.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Chassis%20finished%2002_zpsko8ra0tt.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Chassis%20finished%2003_zpsbca5p4cp.jpg

It has weighed in of plan at 285kg with the changes and fish plates fitted.

I now have to turn it over again and fit the axle, air bags, shocks and hand brake cabling. Then I can start on the walls.

Title: Re: jclures DIY crossover camper
Post by Derek on Jul 22nd, 2016 at 9:06pm
Looking good John.

Title: Re: jclures DIY crossover camper
Post by GROMET on Jul 22nd, 2016 at 9:50pm
Looks very impressive 

Title: Re: jclures DIY crossover camper
Post by Chally on Jul 22nd, 2016 at 10:54pm
Lookin' good.

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Jul 28th, 2016 at 10:05pm
I have started to prime and paint the chassis, I am only painting where I need to so I can turn the chassis back over onto it wheels so to speak.
Fitted the axle and link arms with the spacers instead of the air bags, and now working on the hand brake cables.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Suspension%20painted%2002_zpsc4hknmaz.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Suspension%20painted%2001_zpsjxosn7le.jpg

Title: Re: jclures DIY crossover camper
Post by jclures on Jul 28th, 2016 at 10:11pm
Derek, Gromet and Jeff thanks for the comments, I am now happy with where I am at on the new camper, but I feel I am in go slow mode, Bonnie is keeping an eye on me in case I get crook again, saying I can only do a bit every day.  :-?

Title: Re: jclures DIY crossover camper
Post by Derek on Jul 28th, 2016 at 10:28pm
Slowly but surely John. Cheers

Title: Re: jclures DIY crossover camper
Post by GROMET on Jul 29th, 2016 at 5:32pm
John, remember Rome wasn't built in one day either I am sure that you will get there

Title: Re: jclures DIY crossover camper
Post by jclures on Jul 29th, 2016 at 8:19pm
I have been asked what paint I am using so this is what I am doing,  I first cleaned with some petrol, I found this removed the weld through splatter spray well. Next septone rust converter, then degreased, then sprayed with dmc zinc, over anything I thought needed a coat. Then black zinc before painting chassis black. When finished I will give where it is visible a coat of hammer finish and under I will paint septone under body protection.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/chassis%20paints%2001_zpsh6arfipe.jpg


Started on the brakes today, I am going to use Commodore VT VX rear brake cables to go to the drums, so I need to modify the drums to work, I cut a slot in the leaver so the cable will go over it and welded a tube which I then cut a slot for the cable to fit. I still need to make a keeper on the chassis for the other end over the weekend.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/drum%20brake%20mod%2001_zpsy9sfjkpc.jpg

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 4th, 2016 at 7:34am
I have stopped working on the brake system for now, I am thinking on how I will run the wire to the brakes and keep it tidy.

So while I do this I had a few new bits turn up, one of these are the four drop down legs.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20camper%20parts/new%20legs%2001_zpsvmyjtwox.jpg

I had made the mounting points on the chassis already, so all I need now to do is weld the leg mounting bracket on and then fit the legs.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20camper%20parts/new%20legs%20fitting%2001_zps3ylnznbu.jpg

Back leg.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20camper%20parts/new%20legs%20fitting%2002_zpsvctsqwfe.jpg

Front leg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20camper%20parts/new%20legs%20fitting%2003_zpsttd8z6eq.jpg

Now I can get back to the brakes.

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 5th, 2016 at 8:58pm
Hand brake cable is is finished.
I have made a extra bracket on the drum brake backing plate to hold the hose which the wire will run through, to the electric brakes. I thought by running the wire and cables together should make a tidy way and keep them safe on the road.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/brake%20cable%20fitted%2001_zpsu5hcdrmp.jpg

For the wire part of the hand brake cable I am using pulleys on any bend of the cable.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/brake%20cable%20fitted%2002_zpsohe15ert.jpg


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/brake%20cable%20fitted%2003_zpsleducis5.jpg

Hooked up and finished. I will remove it before painting but the work in now done.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/brake%20cable%20fitted%2004_zps8crt6axv.jpg

Now I need to finish of a few other jobs so I can turn it over and start on the main camper.

Title: Re: jclures DIY crossover camper
Post by Chally on Aug 7th, 2016 at 1:50pm
Excellent; very neat JC.

Jeff

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 10th, 2016 at 6:57pm
I get even more amazed every time I look at this thread.  You are doing a fantastic job John

Title: Re: jclures DIY crossover camper
Post by TBF on Aug 10th, 2016 at 7:41pm
I've seen John's planning and drawings for the xover.
The man's a genius.

Aart

Title: Re: jclures DIY crossover camper
Post by shackles on Aug 10th, 2016 at 8:03pm

TBF wrote on Aug 10th, 2016 at 7:41pm:
I've seen John's planning and drawings for the xover.
The man's a genius.

Aart

I second that.

Title: Re: jclures DIY crossover camper
Post by GROMET on Aug 10th, 2016 at 10:25pm
It is a pleasure to see a man who sees a problem,  then looks at the problem, sees the answer then fixes it
WELL DONE


Title: Re: jclures DIY crossover camper
Post by jclures on Aug 15th, 2016 at 6:42pm
No genius here, just a busted and broken down tin miner. But I do enjoy making things and sharing them with others. If someone sees what I am making maybe they will also have a go.

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 15th, 2016 at 7:31pm
My new Jockey wheel arrived, I thought about using the one I had, but I thought maybe I should get a new one which could be better suited.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/New%20jockey%20wheel%2001_zps9gjy0vbm.jpg

The first problem is now I have it is, I made the chassis to take the one I had, and the new one has a different bolt pattern.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/New%20jockey%20wheel%2002_zpsyj0ld8hx.jpg

I will also need to change the wheel angle on the wheel lock as I want the wheel to sit flat not hanging down.

I have also changed my mind on where I want the air tank to be located under the chassis. Now it is getting close to being finished, I realised I could fit it in between the suspension arms and behind the water tank. This will protect it better I think than where I had planed on mounting it in front of the water tanks..

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Air%20tank%20mounted_zpsfxrbmua7.jpg

I also have made a set of side rails for the back end of the camper, my thinking is this could be  insurance for it when I go bush.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Camper%20rear%20sliders%2001_zpsswt8qkue.jpg

I will now remove all the bits of the chassis and paint it, ready to turn over for the last time I hope.

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 15th, 2016 at 7:42pm
Taking shape more an more John.  Looks great.

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 15th, 2016 at 8:29pm
Thanks Derek,

On another  note the off topic post link appears not to work, upgrade problems?

I have caught up with my posts on the camper now. I finished painting at beer o’clock time today, very happy with how it now looks.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/chassis%20painted%20black%2001_zpsmkciylng.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/chassis%20painted%20black%2002_zps5ha9dtmt.jpg

Ready to start to put it together and turn it over for the next stage.

Title: Re: jclures DIY crossover camper
Post by Chally on Aug 15th, 2016 at 8:33pm
Impressive John!

Jeff

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 15th, 2016 at 8:35pm

jclures wrote on Aug 15th, 2016 at 8:29pm:
On another  note the off topic post link appears not to work, upgrade problems?


Aart accidentally posted in here, instead of his Cape York Trip with a photo of his dinner cooking tonight so I moved it.  It is opening on the first post on that thread though and not the one I moved.

That little Off Topic post is inserted automatically by the software.  Have removed it   :D


Title: Re: jclures DIY crossover camper
Post by jclures on Aug 23rd, 2016 at 8:16am
It is now all together and movable. I have fitted a safety suspension chain to the axle as I was worried about the travel down, and relying or shocks to do this, although I took no photos.

Air bags being tested.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Air%20Bag%20inflated%2002_zpskrgc18r9.jpg

this is when I decide to put travel stops in as I thought it might be needed.

The chassis now finished.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Rolling%20Chassis%20Finished%2002_zps2aejxojk.jpg


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Rolling%20Chassis%20Finished%2001_zpszwkc2vv0.jpg


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/Axle%20chain_zpsucf3ckrj.jpg


It seems to toe well, back well and with a ball weight at this stage of 76kg. This is the weight I expected with the chassis finished, jockey wheel, wind down legs and water tanks fitted.


Now I can start the next stage.

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 23rd, 2016 at 8:24am

jclures wrote on Aug 23rd, 2016 at 8:16am:
I have fitted a safety suspension chain to the axle as I was worried about the travel down


My van has webbing straps fitted for that.

All looking very good John.

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 23rd, 2016 at 10:22am
I have seen quite a few off road campers use chain so I thought I will go with a good heavy chain and see how it goes. I would like to go to a cable but I don't have the gear here to crimp it well enough.

Title: Re: jclures DIY crossover camper
Post by Chally on Aug 23rd, 2016 at 10:23am
Very impressive John!

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 28th, 2016 at 8:34pm
I have achieved quite a bit since my last post, with the help of my free unwilling workers  (Bonnie and our son David).

The first stage of the camper frame is taking shape, so far it has worked out close to my planing, although I have updated the plans as I have worked on it.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/Shell%20stag%201%20frame%2002_zps1zl3cylp.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/Shell%20stag%201%20frame%2001_zpsdj6sasv0.jpg

Title: Re: jclures DIY crossover camper
Post by Chally on Aug 28th, 2016 at 8:44pm
It certainly is taking shape mate. Keep the updates coming. :)

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 4th, 2016 at 2:23pm
I now have the walls to the point I can soon start on the roof frame. The side walls are finished with some triangulation built into them and the mudguard framing is also done.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/Shell%20stag%201%20frame%2003_zps7v2ls6bv.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/Shell%20stag%201%20frame%2004_zpsa65bqfbv.jpg

I have gusseted the door frames with a short internal wall, this will when finished also be sheeted.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/door%20frame%20support%2001_zpskrtisrku.jpg

Some of my left hand collection, without plenty of G clamps I would be stuffed.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/my%20left%20hand%20colection%2001_zpskicmmzfh.jpg

I do need to make a temporary frame to build the roof to but that should not take long, then onto the roof framing.

Title: Re: jclures DIY crossover camper
Post by Derek on Sep 4th, 2016 at 6:29pm
Wow John, that is amazing.  It is even starting to look like a small off road caravan.

Title: Re: jclures DIY crossover camper
Post by TBF on Sep 4th, 2016 at 7:09pm
That caravan isn't going to fall apart John.
Got to be way stronger than anything else on the market.

Aart

Title: Re: jclures DIY crossover camper
Post by shackles on Sep 4th, 2016 at 7:33pm
Coming along very nicely John. Have you and Bonnie started planning your first big trip yet?
You do realise that the first COG you take it to there is going to be a lot of sticky beaks. ;D

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 5th, 2016 at 8:17am
Derek it is taking shape, it is good to see the ideas I had in my head are now being able to see. :)
Aart, no I don't think it will fall apart any time soon. :D
I have no idea :-/ where we will give it a test run to yet shackles. I think I would like to try a short trip before I finish it to make sure I am happy with it  though.

Title: Re: jclures DIY crossover camper
Post by Saltbush Bill on Sep 5th, 2016 at 7:07pm
Nice work JC...its really starting to  come together now. [smiley=thumbsup.gif]

Title: Re: jclures DIY crossover camper
Post by Rolly66 on Sep 6th, 2016 at 8:14pm
Looking the business now jc
Can't wait to see the finished project  :)

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 8th, 2016 at 7:51am
I have now settled on the design of my hopefully lifting roof.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20Camper%20drawings/3550%20folding%20%20wall%20camper%20roof%2075mm%20front_zpsoi0o2agt.jpg

This has now been simplified as I was thinking of a two angled front, but thinking about it I thought I need to be able to mount solar panels somewhere with a flat surface.

I am working now on the main bed base frame so I can put a deck on it so I can make a safe working area as I build the roof.

This is what I am planing.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20Camper%20drawings/3550%20I%20am%20building%20bed%20frame_zps8haxkn5o.jpg

The bed frame started.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/bed%20framing%2001_zpsjlp2cks4.jpg

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 8th, 2016 at 7:56am
Rolly66 I can't wait either, although it is going to slow up soon as I have been working with materials I had already brought. Soon I will need to start buying in more bits and I will do that as I can afford to buy them.

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 11th, 2016 at 8:48pm
I never got done what I planed to do this weekend.
I am pleased though I did not get on with the actuators with some information another forum member has given me. I will now go back and rethink my sliders I had been working on to see if I can use these tube sliders from hub products.

http://hubproducts.com/collections/tube-sliders

I did however start to test fit the flooring. I am doing this as I have now fell through the chassis more than once working on the walls, (I am a slow learner) so this is being done for my own safety.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/first%20flooring%20test%20fit%2002_zpsrek7ccht.jpg


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/first%20flooring%20test%20fit%2001_zps8bzmsiop.jpg

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 13th, 2016 at 7:20am
I needed to work out if I can fit the 50mm box in as my slider instead of the 40mm I was going to use. After a test fit I think it will be easier now, as it has given me a chance to rethink my brackets I need to make to hold it in position in the wall cavity I had allowed for it.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/test%20fit%2050mm%20actuator%2001_zps6xlvjsgu.jpg

So I have now ordered 4 X 50mm tube sliders.

I also received my portable grey water tank, I think I should be able to carry it in the front box in approximately this position.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/grey%20water%20tank%20arrived%2001_zpszhfm4gbi.jpg

I have in the mean time been able to get some more of the floor cut out and placed into position ready to be glued down.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/more%20floor%2002_zpszmed70nz.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/more%20floor%2001_zps5s5jt8mu.jpg

Title: Re: jclures DIY crossover camper
Post by TBF on Sep 13th, 2016 at 7:46am
What size is that grey water tank John.

Aart

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 13th, 2016 at 7:56am
40l from ebay Aart
http://www.ebay.com.au/itm/252418695048?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
It should cover me if and when i need it.

Title: Re: jclures DIY crossover camper
Post by Derek on Sep 13th, 2016 at 8:02am
Mine is a similar 40 litre one.  Have had it for near on 4 years now.  Has seen use on our current and previous van.

Must admit though it has not seen a huge amount of use but very handy when needed.
greytank4.JPG (131 KB | )

Title: Re: jclures DIY crossover camper
Post by TBF on Sep 13th, 2016 at 3:06pm

jclures wrote on Sep 13th, 2016 at 7:56am:
40l from ebay Aart
http://www.ebay.com.au/itm/252418695048?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
It should cover me if and when i need it.


Thanks John.
I see they come in two sizes. 40 litres isnt much if you have 2 showers and a sink of dishes.
25 litres is way too small.

Aart

Title: Re: jclures DIY crossover camper
Post by Derek on Sep 13th, 2016 at 3:32pm
Any bigger than 40 litres and you will never move it Aart.  Mine needs emptying everyday when we use it.  I just pick it up and roll it onto a tarp on the back seat of the cruiser and drive to the nearest dump point.

Title: Re: jclures DIY crossover camper
Post by TBF on Sep 13th, 2016 at 6:48pm

Derek wrote on Sep 13th, 2016 at 3:32pm:
Any bigger than 40 litres and you will never move it Aart


The equal of 2 full Jerry cans. That's heavy.
Glad there isn't too many places that require fully self contained yet.

Aart

Title: Re: jclures DIY crossover camper
Post by Chally on Sep 13th, 2016 at 9:53pm

TBF wrote on Sep 13th, 2016 at 6:48pm:
Glad there isn't too many places that require fully self contained yet.


I agree mate.

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 14th, 2016 at 7:43am
As far as I know, up here there is no need to have a grey water tank. But I will happen I guess, so I am just hedging my bets for the future.
Plus if I travel around there are so I am told,some camp areas that require one
For the price I brought of ebay it seams the easiest way around the problem. :)

Title: Re: jclures DIY crossover camper
Post by Derek on Sep 14th, 2016 at 11:31am
Just about every second free camp in and around the Gippsland in Victoria have a sign same or similar to this so yes the numbers are growing.
marlo1.jpeg (200 KB | )

Title: Re: jclures DIY crossover camper
Post by TBF on Sep 15th, 2016 at 3:39pm

jclures wrote on Sep 13th, 2016 at 7:56am:
40l from ebay Aart
http://www.ebay.com.au/itm/252418695048?_trksid=p2057872.m2749.l2649&ssPageName=STRK:MEBIDX:IT
It should cover me if and when i need it.


Mine should be here next week.
Will be handy for the 6 weeks away in November/December

Aart

Title: Re: jclures DIY crossover camper
Post by shackles on Sep 15th, 2016 at 6:22pm
I am thinking of using 2 x square 20lt plastic containers. Is that passable?
th_3_.jpg (4 KB | )

Title: Re: jclures DIY crossover camper
Post by Derek on Sep 15th, 2016 at 6:39pm
I do not see why not.  The idea is capture the grey water and remove it from site.

See lots of discussion about this on various forums and from what I am reading there are only a couple of camp grounds that insist on having your grey water tank built in.

We just give them a miss :)

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 21st, 2016 at 8:29pm
The tube slides arrived, so now I cam think about starting the sliders for the actuators.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/SHS%20Sliders%20bush%2001_zps1e4n7an5.jpg

I am trying to get the sliders at 90deg this way I hope not to have any problems lifting the roof.


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/setting%20at%2090%20deg%2001_zpssyuieqbu.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/setting%20at%2090%20deg%2002_zpsc1tagr87.jpg

One done, now to work on mounting the actuator to the slider.

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 13th, 2016 at 9:44am
I have had some problems as I started welding in the internal front wall. The outer front left side wall pulled in by about 10mm at the top. This I could not get back into place without some major repairs. I ended up by removing it completely and redesigning it again this time with a support on the inside.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/camper%20roof/new%20left%20front%20wall%2001_zpsoiackgpi.jpg


I have now finished the two rear roof actuators, but I have realised I need to get the roof at it's correct height before I can weld in the roof mounts.


http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/camper%20roof/two%20rear%20actuators%20now%20fitted%2001_zpswf9pyywd.jpg


I want the roof to ride on a plastick track of some sort. I first thought the blue plastick you use on boat skids, and this is still a possibilty, but I would need to trim it to fit and get it to the right thickness of around 8mm.
I was walking through Bunnings the other day and had an idea that the plastick garden edging might work.

https://www.bunnings.com.au/icon-plastics-75mm-x-6m-jarrah-garden-edge_p3321163

So I have now brought a length of edging 75mm wide and 7mm thick.  This I have now run it across my saw bench and brought it down to 23mm strips.

This I am fitting between the roof and walls, it is also in the side of the framing to keep the roof from moving sideways  as well.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/camper%20roof/right%20side%20roof%20insert%2001_zps5wwh7fqt.jpg

Once fitted this gives me the gap on the outside for the weather seal to be fitted when finished.

Weather seal gap

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/camper%20roof/weather%20seal%20gap%2001_zpsgbw98oex.jpg

I now am working on the left side to get these trims in place so I can finish of making the actuators front and rear.

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 23rd, 2016 at 11:53pm
I have got back onto working on the camper after out trip away.
I have now finished all four actuators and sliders. The first test lift has worked, although the actuators are running at different speeds going up and down. But they are working well enough, I can try swapping the slowest or fastest for the spare unit I have.
I have however thought this might be a problem so I have made the connection to the roof flexible enough that this should not be a big problem.

Lifted the roof just fits in my shed.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/camper%20roof/roof%20up%20first%20time%2001_zpsowj9txnn.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/camper%20roof/roof%20up%20first%20time%2002_zpsnaj9s9es.jpg

roof mounting point.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/camper%20roof/roof%20up%20first%20time%2003_zps2de6heu9.jpg

looking down through the  main shell rear double wall frame.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/camper%20roof/roof%20up%20first%20time%2004_zpsjszezoux.jpg

My testing has now let me think about the next stage of the build. I have also checked on the lifting times going up in 2.35m and down in under 2m. 

Title: Re: jclures DIY crossover camper
Post by TBF on Dec 24th, 2016 at 9:56am
Welcome home John.


Aart

Title: Re: jclures DIY crossover camper
Post by Derek on Dec 25th, 2016 at 4:50am
Good to see you back working on it.  Looking good.

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 25th, 2016 at 8:19am
Thanks Derek and Aart, We are back home after a really good trip. I should put a trip report up I guess.
Every one have a merry Christmas.

Title: Re: jclures DIY crossover camper
Post by shackles on Dec 25th, 2016 at 9:18am
Welcome back John.

jclures wrote on Dec 25th, 2016 at 8:19am:
I should put a trip report up I guess.

When you get time. Merry Xmas.

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 30th, 2017 at 10:45am
I spent the weekend getting my metal break to work, some of my ideas I had to change, but over all I think it will be ok. Still needs a clean up and tidy up some bits as they are a little rough around the edges but it now works.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/work%20shop%20tools/sheet%20metal%20break%20001_zpsvilgwc51.jpg

The clamping is done by using 30mm captive nuts with floating bolts, the bar tensioner is also using this idea.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/work%20shop%20tools/sheet%20metal%20break%20002_zpsjgtb6oez.jpg

I found I needed to put a arm back to make the clamp work properly.

My first use of the metal break was to start folding my mudguards.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/folded%20mud%20guards%2001_zpsvo2iy4sz.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/folded%20mud%20guards%2002_zpscu2obf8y.jpg

They are ready now to bend into there final shape.

Title: Re: jclures DIY crossover camper
Post by Derek on Jan 30th, 2017 at 11:46am
Looking good John

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 30th, 2017 at 9:11pm
Derek I hope I can make a bit of progress for a while now, things had slowed down to a crawl.

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 30th, 2017 at 9:26pm
First mudguard test fit, I still have to make the inside wall of the mudguard, but I like the look of what I have made though.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/New%20camper%20started/first%20mudguard%20clamped%20in%20place%2001_zpsdeecpkt5.jpg

Title: Re: jclures DIY crossover camper
Post by Derek on Jan 30th, 2017 at 9:35pm
John

Not sure if you have posted but what do you expect your Tare and ATM to come in at???

Thanks

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 30th, 2017 at 9:56pm
Derek, at present if my maths are right it should weigh around 1000kg, I hope once I have it toeable I will get a permit and take it down to our local weighbridge.

I am planing on the tare being around 1800kg and a atm of just under 2500kg. If I can get it lighter I will be happy, but these are the figures I started with during the design stage.

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 2nd, 2017 at 10:57pm
I have finished fitting the mudguards. I had a bit of a rethink on how I wanted them but they are now fitted and then the joints sealed with a sealer. I think I got more of this sticky black stuff on me more than the job I was doing.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/Mudguards%20finished%2001_zpso8m7ujhy.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/Mudguards%20finished%2002_zpspasia15c.jpg

I have also fitted the first of the flooring, I thought as I had already made a mess I might as well do a good job.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/first%20flooring%20down%2001_zpsp4zr01xo.jpg

The next job is to get some more of the flooring down. I will feel a lot safer once I have finished the floor, as I have fell through the framing on several occasions, I just tell myself I am a useless prick and hobble of and recuperate over a beer or two.

Title: Re: jclures DIY crossover camper
Post by shackles on Feb 3rd, 2017 at 7:17am

shackles wrote on Apr 2nd, 2016 at 9:54pm:
How long do you think it will take to build John?


jclures wrote on Apr 2nd, 2016 at 10:04pm:
I don't have a set time, but I work only my shoulder is not giving me trouble, so I would be just guessing if I said this time next year.

I don't think you are going to make it John. ( To many beers and holidays) ;D ;D

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 9th, 2017 at 10:25pm
You could be right. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 9th, 2017 at 10:25pm
I have had a good few days, and I feel I am now starting to see some of my ideas starting to come together.

I did get some more of the flooring down, and spread more of the black stuff around. I must say the air riveter works well, I also brought a air sausage gun that is making life easier as well.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/More%20flooring%20down%2001_zpshuwu7ivk.jpg

I then moved onto the main door, this when finished will be in two half’s. The bottom section I am fitting in a vent and dust filter, so I have allowed for the filter in the door frame.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/main%20door%20bottom%20frame%2001_zps9quaninu.jpg

With the roof down this is the locking section.

But for me today was the test. I have said all along, I wanted folding walls, so today I finished the main frame of the left hand side wall. This is the hardest wall to make as it also has a section of the door. It is also if it works as planed the first and last wall to setup when setting up the camper.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/left%20folding%20wall%20started%2001_zpslrvythpo.jpg

When it is folded down with the roof down, the end walls will be under this wall.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/left%20folding%20wall%20started%2002_zpsjwqtrroj.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/left%20folding%20wall%20started%2003_zpsppqimm5w.jpg

folded out with the window in position.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/left%20folding%20wall%20started%2004_zpsxuxnixjf.jpg

I still now need to make the top half of the door, but I feel I am now making progress.

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 13th, 2017 at 10:13pm
I have started on the top section of the main door, this I thought I might make using aluminium. My welding is a little scratchy as it has been some years since using aluminium. I also need to remember to turn on the gas, as apparently this helps. ::)

Any how I managed to get the top of the door frame started, this is also in two sections to allow for the folding and clearance for the roof to close.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/door%20top%2001_zpsepjbgimj.jpg

I plan on using j seal for the main joint and a piano hinge will allow the lower 50mm section to fold up.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/door%20top%2002_zpscxf62wtf.jpg

Title: Re: jclures DIY crossover camper
Post by Derek on Feb 14th, 2017 at 11:21am
Coming together nicely.

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 18th, 2017 at 10:37pm
I have not been able to get on with much recently for other reasons, but I have now got most of the flooring down.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/more%20floring%20down%2002_zpsetfrkrqm.jpg

front storage area floor.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/front%20box%20floor%2001_zpsxmuhcybq.jpg

I have also been working on the air bag air supply, I brought a paddle switch for each airbag, but I have found one of the switches is leaking internally. I can hear the air leaking out, I first thought it might be the connections, after testing with soapy water I then looked at the valve it self.

For now I have removed the valves and just filling the air bags as one as I needed to test the towing behind my Nissan.

The camper at the correct ride hight.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/camper%20shell%20first%20tow%2001_zps0kc55xax.jpg

The blue bits on the front are to stop me hitting my head on the frame as I am working on the camper.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%202/camper%20shell%20first%20tow%2002_zpse7i0hccf.jpg

After leaving it sit for 24hours, it is still now loosing around 10lbs out of the air bags. Which one I don't know yet. But I will work on this later for now, as I have ordered some bits that might help fix the problem.

Title: Re: jclures DIY crossover camper
Post by Derek on Mar 18th, 2017 at 10:44pm
Very impressive John.

Title: Re: jclures DIY crossover camper
Post by Saltbush Bill on Mar 19th, 2017 at 1:32pm
Whewwww that's a big job to take on.
Gotta admire your patience and skills to be able to build something like that. [smiley=thumbsup.gif]
SBB

Title: Re: jclures DIY crossover camper
Post by TBF on Mar 19th, 2017 at 8:14pm
Looking good JC.

Aart

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 26th, 2017 at 10:00am
Thanks for the comments, SBB I can tell you I am not very patient. I now need to get the camper built with now selling our old camper. I did not plan on selling it just yet, but a fellow came to visit with cash in hand.

I have now got most of my composite panel for the inside and out side walls, and also the aluminium sheeting for the folding walls plus all the sheet insulation for the roof and walls.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20camper%20parts/more%20sheeting%2001_zpsefavoofw.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/new%20camper%20parts/sheeting%20and%20insulation%2001_zpsfjn7dijd.jpg

I am only using the .8 aluminium for the folding walls to keep them as light as I can. But I will have to paint these walls at some stage though.

The first of the small door frames is now made.
I am making rivet in frames for the door seals, when finished I will sikaflex and rivet them in place. The seal I am using on these doors are the medium size pinch weld.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/first%20door%20frame%2001_zpsgwu8ofaq.jpg

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/Shell%20stage%201/first%20door%20frame%2002_zpskg5659za.jpg

I needed to get these door frames started as I am getting the holes drilled in place so I can start running the wiring through the steel framing.

Title: Re: jclures DIY crossover camper
Post by jclures on May 11th, 2017 at 9:13pm
I have now got back onto my folding walls. This has been dragged out a bit as I was not happy with the framing and I decided to rebuild it.
Now I am happy with it I have started to sheet the out side with .8mm aluminium sheeting. I have made a temporary bench using my old box trailer, this way I am out side and near where the sheeting can be cut easily.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/folding%20walls/sheeting%20first%20fold%20wall%2001_zpsclwftqcg.jpg

All clamped up, I am using old batteries as weights around the window framing.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/folding%20walls/sheeting%20first%20fold%20wall%2002_zpsyyixut2y.jpg

Once I have the sheeting trimed I have test fitted the window.

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/folding%20walls/sheeting%20first%20fold%20wall%2003_zpsud7y3f4s.jpg

Now I can get onto the inside sheeting on this wall.

Title: Re: jclures DIY crossover camper
Post by Derek on May 11th, 2017 at 10:07pm
Looking good John.

Were you keeping those old batteries just for the job :)

Title: Re: jclures DIY crossover camper
Post by jclures on May 12th, 2017 at 9:20am
I did actually keep them for the job. I used them as well on the floor as weights, and they will get a work out when I do the roof. :)

Title: Re: jclures DIY crossover camper
Post by jclures on May 15th, 2017 at 8:25am
The first of the folding walls is now made, only three more to go. :)

http://i217.photobucket.com/albums/cc145/jclures/Our%20New%20Camper/folding%20walls/first%20folding%20wall%20made_zpsjthxvxhk.jpg

When I have them all finished I can then paint them all together. I have run the side light wiring through these walls internally, I just hope I have placed them right as I can not go back now.

Title: Re: jclures DIY crossover camper
Post by Bello on Jul 23rd, 2017 at 7:39am
Absolutly GREAT, but how much will it weigh? You may need a Mack truck to tow it !

Hope I see it on the road someday when travelling.

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 1st, 2017 at 8:26pm
Bello I think around 1850kg with the two water tanks full, two 9kg gas bottles and two spare tyres. Fingers crossed I have done my maths right.

I have finished the frame of the roof in the last few days, with only a couple of things to tidy up.
I have added a couple of sections to mount my solar panels to plus all the holes for wiring have also been done.

I also thought it was time to test the lifting with a dummy load, so I lifted three rims and tyres on top, which I weighed at 90kg. It lifted to full height in 2minutes and 45seconds. No noticeable difference to no weight at all.

I am still now undecided if I should now remove the roof and paint it ready to fit the lining and outer sheeting or get back to finishing my folding walls.
roof_frame_finished_01.jpg (148 KB | )
Roof_lift_test_01.jpg (153 KB | )

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 1st, 2017 at 10:06pm
Thanks for the update John.  Looking good.l

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 10th, 2017 at 9:31pm
I have now started on the inside fit out of the camper.
I had a few ideas when I started to build the camper but as I went on things changed due to costs and a change of direction.
One thing we wanted was a shower and toilet inside, this has been rethought through many times as I have been building it, but it now has taken shape, along with the inside benches.

The other problem I had was with the fridge. When I first started the fridge was to slide out beside the door, on the out side. But due to a new fridge I have had to rethink this plan. I first tried to build it inside, bur it was not a good fit. So back to plan A, alter the angle grinder was used a new hole size was made to give the fridge the space I needed.

I am now working on the inside storage drawers and shelving and bench top.

Toilet_shower_Started_01.jpg (148 KB | )
fridge_slide_made_01.jpg (151 KB | )
fridge_slide_made_02.jpg (127 KB | )

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 20th, 2017 at 7:58pm
Have only just seen your update John and am amazed at the strength you are building into it.

When I look at how commercially made vans are put together I often wonder how they dont fall apart, mine included.

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 21st, 2017 at 7:26am
Derek I guess the reason is weight, I new from the start of my build it will be heavier than most. Since I started with it I think as I work through the things the weights have increased a bit due to changing things as I go.
I do add the ideas into my plans on the computer and then up date the weights though.
My slide out kitchen is an example, I compared the weight built wit 12mm ply, all aluminium or steel framed with aluminium sheeting. I have now started building it and I am going with the steel frame option, which actually should be lighter than the ply design I started with.
The thing is though as I have started it I came up with other ideas which has put weight back onto it.
slide_out_kitchen_started_01.jpg (149 KB | )

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 21st, 2017 at 9:28pm
Here is where I am at the moment with my kitchen.
I had originally thought I would use a swing down door, but half way through building it I changed my mind and made a sliding door attached to the kitchen itself.

The door front is a bolt on and has the locking handles fitted.

The sink and all the drawer sliders are fitted, I plan on folding the drawers out of aluminium but I still think I might use stainless steel for the bench tops.

Pots and pans will be stored in the compartment beside and under the sink.

My biggest problem is I don't have enough room to open the kitchen drawer out in my shed at the moment, as it hits my work bench before it is fully out, by about 150mm. I need to move the camper over to allow me to finish the kitchen of, but it will wait for now though.

slide_out_kitchen_started_02.jpg (148 KB | )
slide_out_kitchen_started_03.jpg (137 KB | )
slide_out_kitchen_started_04.jpg (157 KB | )

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 12th, 2017 at 8:48pm
As I have gone on with my build I have thought I should have made the roof actuators adjustable, to allow for changes that I have made. So before I go any further I thought now is the time.

With a bit of 5/8 threaded rod and a frame around the 50mm box this is what I am trying.

I still need to do this to the rear actuators, but for now I am working on the front storage box and also starting to run all the wiring through the wall cavities ready for the sheeting.

Adjustable_roof_actuator_01.jpg (134 KB | )
front_box_wiring_02.jpg (86 KB | )

Title: Re: jclures DIY crossover camper
Post by Derek on Sep 12th, 2017 at 9:22pm
Ahhhhh, the technical bits.

Any 240 volt wiring John or just 12 volt???

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 13th, 2017 at 6:50am
The technical bit all right. I have wire from one end of my shed to the other, as the heavy wire I need to run through the chassis was coiled up as it is nearly impossible to pull through  with the coils.

Mostly 12v but I will have some 240v. I plan on using the the CMS DIY  system for the 240v, that you can buy from caravanplus.com.au. I have a sparkie who will inspect it and connect the circuit breaker earth wire to the chassis, as this is all I require him to do using this system.

https://www.caravansplus.com.au/cms-circuit-breaker-loom-assembly-with-remote-earth-wire-jcbnw-p-16104.html

https://www.caravansplus.com.au/cms-diy-240v-15amp-power-inlet-p-11042.html

I have a 40a battery charger, 600w/1200w pure sine wave inverter and solar regulator with 360w of solar panels to fit as I wire it up.
I just hope I have got enough room with the holes I drilled to fit all the wire though.

Title: Re: jclures DIY crossover camper
Post by Derek on Sep 13th, 2017 at 8:04am
Ahhhh, was going to suggest you having a look at that.  Both my last caravan and my current motorhome have the CMS System.  Seems to be a Jayco thing.

Was very handy when my circuit breaker stopped working on the caravan.  Simple process to just unplug the old one and plug in a new one.

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 15th, 2017 at 7:59am
I have started making the doors for the front storage area. The right door will have the hot water mounted onto it plus access the water filters and grey portable water tank.

The left hand is larger to give room to fit the generator and out board motor when I take it.

I have also fitted the first of the wall sheeting inside the storage area, so I can mount the water filters to the wall. Now they are in place the shelving can be built around them.

I now need to get some of the plumbing done as well, as it will be easier now rather than later on in the build.
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Title: Re: jclures DIY crossover camper
Post by jclures on Sep 16th, 2017 at 8:55am
My plumbing plan is a bit rough but this is what I am trying to do.

The tank filler is off mains pressure, with a regulator in line, when camping all taps are off. Where water is on tap, like a caravan park, a bypass tap is on and it flows through a one way valve, with a second one way valve stopping it flowing back to the tank.

So far the plumbing is going as planed, but I need to fix a leak at the first filter, a little more thread tape is needed.


The elbows and fitting are all screwed to the wall using 4mm nutserts, so they will not move in a hurry.
I am using these fitting though to go through the floor down to the tanks.

Run a bit short one end, so I used a joiner, will fix that later with a new piece of tubing.
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Title: Re: jclures DIY crossover camper
Post by Derek on Sep 16th, 2017 at 9:07am
If you run out of water in your front tank are you able to use water from the rear tank for inside the van??

Also dont forget the red locking clips for all your connectors as I assume they are John Guest fittings.

Title: Re: jclures DIY crossover camper
Post by jclures on Sep 16th, 2017 at 12:02pm
Derek I will use the locking clips on all the hot plumbing and on the cold plumbing where I think it can come undone. I will also use sleeves on the hot plumbing. In the area I am working on at present I can not move the tubing even under pressure the way it is mounted to the wall.

I will be able to transfer if needed from rear to front or front to rear via a external hose.
For my filter system I have a extra filter 1 micron carbon - silver,with a pump to fill from rivers if ever I need to.

http://www.ebay.com.au/itm/gts1-10-silver-impregnated-carbon-water-filter-1-micron/401132272761?hash=item5d6558bc79

The main kitchen is also a carbon - silver final filter for drinking.

http://www.ebay.com.au/itm/silver-gac-carbon-inline-filter-cartridge-8-stops-growth-of-bacteria-6-24/251753435737?hash=item3a9dac9259

I think that should cover most problems with water, other than going the full reverse osmoosis systems.

Title: Re: jclures DIY crossover camper
Post by Derek on Sep 16th, 2017 at 1:47pm
All looks good.

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 5th, 2017 at 8:04am
The myswag gallery has been taken down, I now have a  storage through GoDaddy, and I would like to fix the broken links but I can not see the edit post, to modify each post.

Title: Re: jclures DIY crossover camper
Post by shackles on Oct 5th, 2017 at 9:04am

jclures wrote on Oct 5th, 2017 at 8:04am:
The myswag gallery has been taken down, I now have a  storage through GoDaddy, and I would like to fix the broken links but I can not see the edit post, to modify each post.

I think you only have a certain amount of time to edit your post JC.

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 5th, 2017 at 9:21am
I might have to ask a moderator for help then.

Title: Re: jclures DIY crossover camper
Post by Rufzgutz on Oct 5th, 2017 at 11:58am
It would be easier all round if Derek made you an admin.

You could help tadpole when he is working away as part of your duties  :).

Title: Re: jclures DIY crossover camper
Post by Derek on Oct 5th, 2017 at 9:31pm
John

What are the brass connectors called that go through the floor.  I should be picking up my new trailer for the Motorhome next week and will be fitting a water bladder to it but need to take the piping through the sides and this looks neat.


Title: Re: jclures DIY crossover camper
Post by jclures on Oct 5th, 2017 at 9:41pm
They are called a bulkhead fitting, I brought them on ebay, $14.59 for 5 x  12mm fittings.
They must be available locally but I have not found them at my local stores.

Title: Re: jclures DIY crossover camper
Post by Derek on Oct 5th, 2017 at 9:58pm

jclures wrote on Oct 5th, 2017 at 9:41pm:
They are called a bulkhead fitting, I brought them on ebay, $14.59 for 5 x  12mm fittings.
They must be available locally but I have not found them at my local stores.


Thanks for that.

I always find it easier to get things from eBay China.

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 6th, 2017 at 10:25pm
I am now working on sheeting the inside lining, this has been a long time coming I feel.
Any how the first sheet is up.

working on the next wall now.
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Title: Re: jclures DIY crossover camper
Post by jclures on Oct 18th, 2017 at 8:05am
I am not to far away from getting the camper ready to test, so I am revisiting the controllers for the air bags.
I first went with simple air paddle controllers, one of which I could hear it leaking air. In retrospect I should have pursued the leaking unit from the seller but I was not sure if it had a warranty or not due to the time from when I brought them.

I then thought go electrical controllers, this was a bad option, in the end as it just made things more complicated than they needer to be.

I looked at a seller on Ebay the other day and they were selling a air paddle controller similar to my first idea but the tubing was a push onto a barb.

I decided to contact the seller directly, so after a google search I found them and rang them up.
We talked about a few things, including my camper build,  as this is why I rang regarding the paddle controllers.
I commented that my air bags slowly leaked down, and that I had  pulled them down a couple of times to try to rectify this but with little avail. It was only a slow leak down but it was enough that I thought I would have another look at them before finishing the camper.
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Thor_Air_Suspension_Manual_paddle_valve_02.jpg (40 KB | )

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 18th, 2017 at 8:08am
I went ahead and ordered the paddle valves from them, through Ebay, and a few days later my parcel arrived.
But it was not as I expected. It was a large heavy box, and once I opened it I new why.

David and Venita from Thor Air Suspension had sent me two new air bags and improved end plated to fix the leak down problem, even though I had not brought the original units from them.
Also a stubby cooler and tube cutter as well with a letter of explanation.

They have not asked anything from me but I thought I should mention what they have done for me on here. Though I will let them know how I find them and keep them posted on how my build is going.

Thor_Air_Suspension_box.jpg (120 KB | )
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Title: Re: jclures DIY crossover camper
Post by jclures on Oct 18th, 2017 at 8:12am
I have now fitted the new air bags, along with the new paddle valves and things are looking up, airbags that is,  :) as they are still up sitting at 75psi.

The back looks a little untidy.

Along with the air lines.
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Title: Re: jclures DIY crossover camper
Post by Derek on Oct 18th, 2017 at 9:47am
Looks like it is coming together nicely John.  Very good customer relations there I must say.

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 19th, 2017 at 9:59am

Derek wrote on Oct 18th, 2017 at 9:47am:
Looks like it is coming together nicely John.  Very good customer relations there I must say.



I would have to agree. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 19th, 2017 at 10:01am
I have finished the front and side inside walls, the inside back wall is a removable panel, so I can access the rear actuators, so I can fit that when the camper is nearly finished.

I now have it ready to remove the roof so I can sheet it, so I have taken it down to my brothers shed so I can lift it of using his lifting gear.

More_inside_sheeting_01.jpg (141 KB | )
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Title: Re: jclures DIY crossover camper
Post by Gromet on Oct 19th, 2017 at 10:07am
Very nice 
Ever considered  going into the private camper order construction business 

Title: Re: jclures DIY crossover camper
Post by Derek on Oct 19th, 2017 at 10:13am
Looking good John.

Your “Supervisor” has a good view from up there. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 19th, 2017 at 10:42am
Bonnie has said, definitely not. ;D

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 19th, 2017 at 10:48am
One of my brothers grand children, he has four of them in his care, two girls and two boys. He has to look after them as they are permanently in his car since his son died.

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 20th, 2017 at 9:36am
Now the roof is off I have started to work on the fittings and the lining. All six overhead light brackets have been fitted as well as the holes through the frame to run the wiring.


I have also made a bracket in the two back corners to carry the strap for the wiring to travel up and down with the actuators.
Then the fun started, the ceiling panels had to be flexed into place, as they were a tight fit. Once in they were not coming out again.


I still have the narrow wall sections to finish before turning the roof over to fit the single roof sheet in place.
roof_off_01.jpg (139 KB | )
roof_off_02.jpg (138 KB | )

Title: Re: jclures DIY crossover camper
Post by jclures on Nov 5th, 2017 at 8:14am
Well the roof is now finished, bar the trimmings. With some help I fitted on the top sheet.
After checking and rechecking I cut the sheet, and grooved the underside to make the bend for the roof.


Then it only was a simple job of gluing the sheet down and clamping.


Anything loose in the shed was then put on top as a weight.


All I need to do now is trim the edges down and then fit the edging. I might fit the solar panels next as well, as it should be easier when the roof is off the camper.
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Title: Re: jclures DIY crossover camper
Post by Derek on Nov 5th, 2017 at 10:15am
Amazing.  Do you have a timeline for finishing John or just as much as you can when you can??

Title: Re: jclures DIY crossover camper
Post by jclures on Nov 5th, 2017 at 8:51pm
No I don't really, but if I could I would like to start testing it in December. If that does not happen I will not be worried to much.

Title: Re: jclures DIY crossover camper
Post by jclures on Nov 11th, 2017 at 10:27pm
As I am waiting for some bits for my roof to finish it off, I have started on to main shell again.

The back wall is the first to work on now, I am sheeting the out side, this has come along better than I hoped. I hope the rest goes as well.

Top section first.

Bottom prop plate fitted.

Tail lights done.

The inside back wall is made to be removable. If I ever need to work on the actuators, I can remove the back inside wall in two panels.

I will start on the drivers side next.

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Title: Re: jclures DIY crossover camper
Post by jclures on Nov 30th, 2017 at 8:48am
I have a bit of catching up to do as I have been working trying to get ahead on the camper., The roof on the camper. Using my brothers gantry made lifting it on easy, and it lined up with my actuators first try. It was just a matter of fitting the bolts in and it was done.

I have fitted the solar panels on, but I still will need to wire them in at some stage later on.

I have also been working on on the outside walls, these have come along well, although still need trimming.
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Title: Re: jclures DIY crossover camper
Post by jclures on Nov 30th, 2017 at 9:17am
took this photo after fitting the roof on, it will give you a idea on how it is going to look when finished.

The front storage section has now been framed up, with shelving, the sheeting is the next thing to do. I found I had made a mistake in where I fitted the water filters so then now need a plumbing change. Better to fix it now than later on.

camper_unfinished_preview_01.jpg (194 KB | )
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Title: Re: jclures DIY crossover camper
Post by Derek on Nov 30th, 2017 at 9:43am
Absolutely amazing John.

Thanks so much for continuing to keep us updated.

Title: Re: jclures DIY crossover camper
Post by tadpole on Nov 30th, 2017 at 9:55am
A very impressive build jclures. It's good to see it all coming together now.

Title: Re: jclures DIY crossover camper
Post by TBF on Dec 3rd, 2017 at 10:44pm
Looking good John.
How long before you hit the road with it?

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 4th, 2017 at 8:13am
I am hoping to get it registered this week, it will not be finished but I can then start to road test it to check how I am going with the fittings in place. Now is the time I have to change anything as once it is finished it will be harder to do.

Title: Re: jclures DIY crossover camper
Post by shackles on Dec 4th, 2017 at 8:40am
Have you weighed the trailer yet John?

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 4th, 2017 at 8:47am
I hope to do so as i register it.

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 7th, 2017 at 10:11am
I had hoped to be closer to finishing the camper, but it seems to take me longer to do things than I think I can. I have put of trying to get it ready to register it for a couple of weeks.

Any how I have finished the right folding wall, and started the back folding wall.

I have also sheeted the front storage area, it still needs to have the sheeting trimmed, and fit the doors.
right_folding_wall_01.jpg (112 KB | )
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front_box_sheeted_01.jpg (155 KB | )

Title: Re: jclures DIY crossover camper
Post by Derek on Dec 7th, 2017 at 11:39am
John, are you going to have a gas installation?  If so would you need a certificate from an installer to get it registered??

I see those old batteries being put to good use again :)

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 7th, 2017 at 1:42pm
Derek I am not having any hard plumbed in gas, I talked to a gas fitter locally it was just to hard.  :-? I could not get through to him, if I was to have gas fitted it needed to go in in the framing stage.

Title: Re: jclures DIY crossover camper
Post by Derek on Dec 7th, 2017 at 7:49pm
And so it should. 

I am pretty sure that in every caravan I have owned as well as the motorhome the gas has been the least thing to go in.  Huge holes through the floor and the cupboards as well.  Everyone has been messy.

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 7th, 2017 at 11:34pm
It just annoyed me that I could not get it done at that stage, so I have worked around it.
The hot water is on a swing out door with the gas and water hoses connected, I will use quick fit connectors to connect to the gas bottle. The gas bottle will not have to be moved to do this.
The kitchen, as it is on the out side any how I will just remove the gas bottle from the holder and connect it to the stove, also using quick connect fittings.
It will give me some thing to do as as Bonnie puts the roof of the camper up anyhow. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 22nd, 2017 at 9:05am
I have been a little slack working on the camper. With going to Tasmania for a week and Christmas coming up.
The front solar panel is fitted, even though this is not the panel I brought for the job, I have used this one as it fitted better for the look of the camper I thought. This will give me 360w of solar on the camper in total.
I have also fitted the sheeting on the two front doors, plus fitted the water tank filler. I am yet to fit the corner edging on any of the walls or around the doors and door frames.
front_solar_panel_01.jpg (127 KB | )
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Title: Re: jclures DIY crossover camper
Post by Derek on Dec 22nd, 2017 at 9:21am
Looking all so very neat John.  What glue did you use for the solar panel brackets??

I just noticed that yours is post 200 on this thread.  I have really enjoyed the journey with you.

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 22nd, 2017 at 11:29pm
Derek I have used bostik seal n flex 1, this is what I have used throughout the build, unless I needed it to set faster, then I used seal n flex fc.

Title: Re: jclures DIY crossover camper
Post by Derek on Dec 22nd, 2017 at 11:58pm
Have heard only good things about Bostik but have only ever used Sikaflex myself.

I have two more solar panels to put on the motorhome so may look at Bostik this time.

Thanks.

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 8th, 2018 at 11:17pm
After Christmas I had a little trouble with my main door lock, I had a go at fixing it, but on reflection I decided to replace it. As I had made the door around this stile lock, meant I had to find a replacement that fitted the door. Looking  around I found there were several other brands, which were screwed together rather than riveted.
The new door lock feels better opening and closing now as well.
I have now finished trimming the door and the small side door as well. I have used a pinch weld seal on the inside, and as cover seal on the outside.
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Title: Re: jclures DIY crossover camper
Post by Derek on Jan 9th, 2018 at 10:03am
I have seen that door lock on a lot of caravans and motorhomes.

Looking good John.

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 9th, 2018 at 11:12am
I went with this style lock for that reason, Derek. But I never looked into it enough, I brought one of ebay from a seller who I had brought other bits from, not thinking there were differences in design.
I would have saved myself $80 if I had of thought about it.
The new lock screws together, you can see two of the screws in the image, and the rest are inside the lock. It also has a support plate in the front which makes it stronger.
motor_home_door_lock_screws.jpg (19 KB | )

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 9th, 2018 at 11:42am
I have made a decision, after some consultation with Bonnie,on the walls regarding colour. After all she has to be happy with it as well.
I am going to paint both inside and outside using Septone silver hammer finish.
I have cleaned two of the walls using a aluminium cleaning acid, primed and painted both sides.
I am yet to fit the windows back in, but I am happy with how they look.
I need to get a bit of fine weather, and I will paint the lelt side folding wall.
I am still to make the front wall as well.
Folding_wall_painted_01.jpg (113 KB | )
Folding_wall_painted_02.jpg (122 KB | )

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 18th, 2018 at 7:00pm
A big day today, I took it to the Qld Transport Office and had the camper registered. I had no trouble at all, the only problem was with onlookers wanting a look.

Alter the registration was finished, I took the camper down to the weighbridge. This I was worried about as all my weights have never been able to be checked. I thought it should come in at or around 1640kg at this stage, but it was 1560kg. I am happy with that I can tell you.

As for towing it felt good, I thought it would have had some problems but there were none that I could feel, I hardly even new I had it behind me.
It_is_registered_02.jpg (174 KB | )
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Title: Re: jclures DIY crossover camper
Post by Gromet on Jan 18th, 2018 at 7:18pm
looks very nice indead
it even has personised number plates  ;D

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 18th, 2018 at 8:34pm

Gromet wrote on Jan 18th, 2018 at 7:18pm:
looks very nice indead
it even has personised number plates  ;D


I wish. :)

Title: Re: jclures DIY crossover camper
Post by TBF on Jan 19th, 2018 at 7:59am
Well done John. That weight is very good.
Looking forward to the first photos of the unit setup in camp,

Àart

Title: Re: jclures DIY crossover camper
Post by shackles on Jan 19th, 2018 at 9:09am
Now that build didn't take long. :-X
Looks good but will look even better when it gets dirty. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 19th, 2018 at 9:26am
I am very happy with the weight. I had always rounded up during the build with the calculations of weight, but I did not expect it to be that much.
So by my calculations with water and gas tanks empty it should weigh 1829kg when finished. That is if I don't change anything before finishing. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 19th, 2018 at 9:36am
Time went quick for me, never seemed to get enough time. I will get it dirty soon though. :)

Title: Re: jclures DIY crossover camper
Post by Gromet on Jan 19th, 2018 at 10:05pm
So when can we start putting  in our order  for one

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 19th, 2018 at 11:24pm
When do you think, I have not even finished this one, it will need years of testing before I could say it was ready for release. ;D

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 22nd, 2018 at 7:51am
The three walls I have made are now fitted. I have weighed these wall to see if they are within my weight estimates as well before fitting, including the windows.
I brought some trims to go around the inside of the window frames. These were not allowed for when I made the walls, but with a bit of trimming I fitted them, giving a white edge around the windows.
I am yet to fit the top trim along the top of the walls to hide the joint, but over all I am happy with the look and colour.
All the outside side lights are also now wired in as well. They are just strip led lights with a aluminium shroud  so they look down at around 45 degrees off the walls.

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Title: Re: jclures DIY crossover camper
Post by jclures on Jan 22nd, 2018 at 8:46am
The walls lock together when folded up. On the longs side walls I have the J seal on each end, the back wall then pushes into the J seal and I lock it up with a draw bolt.
This gives me a good weather seal on the corner of the wall, but I need to do something on the bottom corner joint.

folding_wall_lock_01.jpg (120 KB | )
bottom_corner_joint_01.jpg (93 KB | )

Title: Re: jclures DIY crossover camper
Post by Derek on Jan 22nd, 2018 at 9:39pm
I am still fascinated John.

You said you got it weighed after rego.  Didn’t you need a weighbridge certificate for the registration?

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 22nd, 2018 at 10:20pm
Not in Qld, Derek. My understanding is once you exceed 4500kg you do. But up till then it is your responsibility to be right. If you get pulled over and you are over weight you are in trouble.
I did not need a roadworthy certificate either, as I am the manufacture and it had never been registered before. All they did was measure up the trailer and check it complied with the regulations.

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 25th, 2018 at 10:03pm
Not much to show, but I have now a hole ready to work on fitting the kitchen.

I have also have worked on the second hinging part for the main door. I fitted the extra draw bolt as I was worried with my other door lock giving me trouble, I am planing on leaving it there now anyhow, as it also might be used to lock the door together when it is set up.
Kitchen_wall_hole_01.jpg (342 KB | )
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Main_door_top_03.jpg (305 KB | )

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 12th, 2018 at 8:15am
I have finally finished building the last folding wall, and after a test fit I have it ready to paint.
Checking my drawings and estimated weights I thought the bare wall will weight 14kg, weighing the actual wall with hinges and with the window it weighed 15kg.
Some of my weights were unknown when I started as I did not know what I really wanted, so I am happy that the numbers have been this close.
I should be able to paint and fit the wall over the next few days, and that finishes the main construction of the camper.
I still have the inside, the kitchen, the plumbing, the electrics and all the trimming inside and outside to go though.


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Front_F_Wall_TF_02.jpg (343 KB | )

Title: Re: jclures DIY crossover camper
Post by Derek on Feb 12th, 2018 at 8:45am
Coming together nicely John.

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 15th, 2018 at 11:25pm
The front wall is now in, and painted with window fitted. I had a couple of minor issues though. The seals gave me a bit of trouble, I ended trimming them and now they work as they should. I hope so anyway.

Folded down there is not a lot of room inside, but I knew this when I thought I will go with this idea.

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Title: Re: jclures DIY crossover camper
Post by jclures on Feb 16th, 2018 at 10:12pm
The kitchen is slowly taking shape, I hope to paint it over the weekend, then I can fit it and plumb it in. I had planed to put a stainless top on it but for now, I am just using the aluminium sheeting painted.
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Title: Re: jclures DIY crossover camper
Post by jclures on Feb 26th, 2018 at 9:16am
The kitchen is fitted and painted and fitted.
I have only made the door for the storage area under the sink. I thought I would see if I liked the propeller plate shiny side out as the fronts before doing the draw fronts the same. Now it is in though I am happy with the look, so I need to finish the drawers with the same fronts.
The drain from the sink has the outlet on the outside end, I can either just use a bucket under it or use a sullage hose to run the sink water away.
On the inside end of the kitchen I have allowed for 12v power on the kitchen with the grey Anderson plug and the yellow is the wiring to activate the water pump when the sink tap is turned on. The water line is plugged into the 12mm push lock fitting.

After getting it all fitted I found a problem with one of the kitchen drawer runners, I found this plastic bump stop broken. I don't know how but I will need to replace or fix this plastic bump stop. I have had a quick look on the internet but have had no luck finding a new spare part, surely I should not have to buy a new runner just to fix this.
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Title: Re: jclures DIY crossover camper
Post by jclures on Feb 26th, 2018 at 1:34pm
I have just spoke to Furnware Dorset who I brought the draw runners from. I can not buy the bump stop, I will have to replace the whole thing apparently. But they carry a life time warranty so they are sending me a new runner under warranty to replace the one I have. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 1st, 2018 at 5:16pm
I have named the camper, after a lot of consideration on a name, we have now settled on one. Nearly  everyone that has a look at the build here, has made a comment that it shouldn’t brake as I think it has been overbuilt a bit, or it is a bit robust.
This made me think of the word Robustus, after a quick google I found that it was a early offshoot of the human species.

   http://humanorigins.si.edu/evidence/human-fossils/species/paranthropus-robustus

After being called a Neanderthal more than once in my life I thought this suits me.

So here it is, Robustus 355, (the 355 is the length of the main camper and plan number).
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Title: Re: jclures DIY crossover camper
Post by Derek on Mar 1st, 2018 at 10:25pm
Love it John.  Also love the art work mate.

Title: Re: jclures DIY crossover camper
Post by Rufzgutz on Mar 2nd, 2018 at 10:56pm
Robustus  [smiley=thumbsup.gif] [smiley=thumbsup.gif] [smiley=thumbsup.gif]

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 9th, 2018 at 9:12pm
I now have a better idea on how my shower and toilet will look, after making a base frame I have been able to test the shower and toilet.
When I started building I had planed around a different toilet, so I now have a overhang of the toilet base over the shower base. I decider that the price I would have paid for the toilet,  for what I would have got, was to much. I can buy two of these toilets for the same amount, this way I can have a spare bottom tank when travelling,  which I thought was a good idea, and I still have a electric  push button flush.

I also have finished the shower plumbing,  on the inside. I think for me I might put a shower bracket of the roof, as hand held shower heads are no good to me.

I have also been working on the camper wiring again, I still have a bit to do with this but I am making progress.
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Title: Re: jclures DIY crossover camper
Post by jclures on Mar 25th, 2018 at 10:13am
We taken a big step getting the camper ready for camping. The fridge is now wired in , and going, beer is cold that is all that matters.
The kitchen is also getting there, the door is fitted, and the wiring to run the rear water pump is also finished.
So I now hare running water and a cold fridge, ready for Easter camping.

The inside bench and drawers are now starting to take shape, I have folded the drawers up, and riveted them together. If I could tig that would have been a better option, as I do not have that option. rivets are going to do. I will fit drawer fronts and handles on when finished but they will work for now.

The fridge compartment is now also sheeted in, as well, so I can now start on the counter top next. It will have a small sink with the hot and cold tap  plumbed in.

I would like to get some floor covering down as well soon.

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Title: Re: jclures DIY crossover camper
Post by Derek on Mar 25th, 2018 at 12:53pm
Love it, John.

First trip[ next weekend.  Looking forward to the report.

Title: Re: jclures DIY crossover camper
Post by tadpole on Mar 25th, 2018 at 2:10pm
Very nice job. Look forward to hearing how it goes on it's maiden trip

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 12th, 2018 at 7:05am
I have been a bit sidetracked since Easter, as I have decided to do the shed shuffle, this is so I can park the camper in the shed and open the kitchen draw without any problems.

Now for its first outing, the camper towed well, I new it was there but it behaved well behind my Nissan.

I had a few minor problems, the water pump relay wiring needed to be looked at as a plug was not in it socket properly.  I also had a problem with the top half of the main door. The screws I fitted had come loose, these were meant to be changed to different screws before it took it out, but I run out of time.

I am going tho change the rear swing down legs though, the 450mm long legs could not swing down enough, so 400mm legs will now be fitted on the rear.
As it turned out coming home, some how I have damaged one of the front legs, so I can use the replaced rear legs to fix the front leg. The road in to where I went is as rough as I think I would take the camper, I should have taken a few photos of what I just called a road so you new what I meant.

I am also going to fit a new compressor, the one I am using looks like it is only just doing the job, I would have liked the ability to put more air into the air bags to cross a couple of gullies on the road, to give the camper more ground clearance but I could not go higher than 115psi.

As it looked like rain while we were camping, we fitted temporary covers over the actuators, they tell me they are water proof but I have on faith in that claim. I also don't want water entering this section of the camper anyway. We will make proper covers to cover them before we go again I hope out of a reinforced vinyl material with Velcro attachments.
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Title: Re: jclures DIY crossover camper
Post by TBF on Apr 12th, 2018 at 11:17am
Well done John.
Great achievement.
Any big trips planned?

Aart

Title: Re: jclures DIY crossover camper
Post by outback jack on Apr 12th, 2018 at 2:00pm

Great job John  [smiley=cheers2.gif]

Title: Re: jclures DIY crossover camper
Post by shackles on Apr 12th, 2018 at 3:48pm
You have done a great job on your camper John. I hope you and Bonnie have lots of happy camping with it.

Title: Re: jclures DIY crossover camper
Post by Derek on Apr 13th, 2018 at 9:09am
Looks really good John.

Title: Re: jclures DIY crossover camper
Post by jclures on Apr 17th, 2018 at 7:33am
Thanks, I have a bit to go to finish it of, that is if I ever finish it. Aart I have no set planes as yet, I will use it in local camping areas until I am happy with it, then I will see about other trips.

The new compressor I brought from Thor Air Suspension has arrived, now it is here I will test run it before fitting, I would like to run it along side what I already have but I will run them in a test before doing that.

I have also started fitting the hand basin bench in, after framing the front up I have cut down a bench top brought from Bunnings, and fitted a basin into it. I found I will need a 90deg waste though, so I now am waiting on this to arrive before finishing it of.

Thor_Air_Compressor_01.jpg (334 KB | )
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Title: Re: jclures DIY crossover camper
Post by jclures on Apr 18th, 2018 at 7:09am
I thought after using the camper the one thing I found harder was using the treg coupling, so I have brought the McHitch adaptor kit. This seamed like the best option for now, although when I can afford it, I think I will go to the McHitch automatic trailer coupler.




Title: Re: jclures DIY crossover camper
Post by Derek on May 25th, 2018 at 8:38am
Any further updates John??

Title: Re: jclures DIY crossover camper
Post by jclures on May 25th, 2018 at 12:20pm
I have but I have not posted them up yet. :-[
But I am taking it camping this weekend, for a test run. :D About to leave as I type this. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 2nd, 2018 at 9:56am
Bonnie took a video of the roof going up when we went away last weekend, it is a 2.30 minute video.
As the roof is going up it is also lifting the folding wall on the left hand side.


https://www.youtube.com/watch?v=KGuNzs0I9tA&feature=youtu.be


We did take a video of me folding out the folding walls but for some reason it was very blurry.
Next time we go away we will try again to get this video of the wall folding and locking in place.

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 2nd, 2018 at 10:00am
I started planing this spare tyre mount when I made the main camper frame by reinforcing two mounting plates, drilled and threaded  for the main mount.

I am only making one spare tyre for now though, I only have eight rims and tyres in this pattern and size, five on the Nissan and three on the camper.

I have used a house stump threaded captive nut and 25mm thread for the mount.
The hard bit for me was making the swing down carrier. I wanted the wheel when down, to be facing up, this way it is easier for me to fit the spare on the carrier. It took a bit of work to get the thread to line up and the mount to slide into place but it worked out quite well.

I can also still use my tyre cover over the spare tyre, I might have to buy a new one though at some time, as this one is getting a few marks on it.
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Title: Re: jclures DIY crossover camper
Post by jclures on Jun 6th, 2018 at 7:20am
I have even before I finished the camper thought about fitting what you would call a stabiliser bar in the suspension, as I thought it would be beneficial. I looked at a few bars I had here, but none would work with what I have.
I then brought a second hand VX Commodore rear bar after doing a few measurements using the Commodore I have here.
After backing the camper onto my ramp to make it easy to work on I started fitting it, I needed some backing practise anyway.
As it worked out fitting it to the axle was quite easy, and it only took a little work on the link rods to get them to fit.
I am taking it on a trip again soon, so I will road test it on some gravel roads, and a windy bitumen range road which should tell me it it was worth the effort fitting it.

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Title: Re: jclures DIY crossover camper
Post by jclures on Jun 7th, 2018 at 7:05am
Alter giving the flooring a bit of thought I have decided to use a product called Hanwood Planks. I a few of these left over as shorts from a job, so rather than waste them I am using them.

Hanwood is a waterproof vinyl interlocking plank with a rubber backing, and also a good insulator on the floor, Well that is what they claim on the box.
Even though the Hanwood is a floating floor product, I am using sickerflex to hold it in place.

While I am at it I am also tiding up the chassis rails in the doorway with some prop plate.

I hope to have this first floor section finished tonight as I plan on going out to Mt Albion camping this weekend.

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Title: Re: jclures DIY crossover camper
Post by jclures on Jun 14th, 2018 at 7:07am
I have been working on the first of two storage draws at the rear of the camper. I like to have a spot for things and then they can be easy to get when needed, that is why I planed these draws from the start of the build.
I have folded them from some of my leftover aluminium, so I can keep them as light as possible.
This drawer is for the tent pegs, hammer, Ropes double and single as well as the rope springs.
The springs have small shackles on each end, and the ropes have spring clips on them so I can break them down to pack away.
I still need to trim the door edging then this drawer and door are finished.

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Title: Re: jclures DIY crossover camper
Post by jclures on Jun 19th, 2018 at 7:42am
I have started to fix things I am not happy with, and the first fix is the hand brake.

From when I first fitted it, I have not been happy with the hand brake leaver.
I thought was up at to high of a angle when the hand brake was off. It might not seem much but when stepping over the A frame of the trailer, I was worried about tripping on the leaver.

To fix the height when off, it needed a couple of new teeth cut in and a relocation off the roll pin stop. Now the handle sits level when off, not up at the angle it was.

I also thought it took to much force to pull the hand brake on, I had to pull it quite hard to stop the camper being able to roll off.
As I had already used the closest hole to the leaver pivot, I have drilled a extra hole. This has now reduced the force to pull it on. Not much of a change to do, but a much better operation of the hand brake.

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Title: Re: jclures DIY crossover camper
Post by TBF on Jun 19th, 2018 at 8:22am
I've just gone through series of posts again. I saw the chassis when we were there nearly 2 years ago.
You've done a wonderful job on it mate. I wish i had 10% of your ability in that field.


Title: Re: jclures DIY crossover camper
Post by jclures on Jun 20th, 2018 at 8:42am
That 2 years went quick., well it did for me. :)

Title: Re: jclures DIY crossover camper
Post by Chally on Jun 20th, 2018 at 7:29pm
You have done/are doing a fantastic job in building your camper John. I'm sure it is very rewarding for you. I have enjoyed following your build.  [smiley=thumb.gif]

Jeff

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 26th, 2018 at 8:53am
Thanks Jeff, at least now we are starting to get some use from all our work.
At present sorting out some insurance for the camper, I am going with RACQ fo now, being home made is not as easy to get insurance as brought camper.

I am getting the camper ready for it's next trip, so there are a few bits I would like to get done.
The first job I have finished is the kitchen drawers. I did make temporary drawer runner frames to work out what I wanted, which I now have replaced with folded aluminium drawers, and drawer fronts.
I have also lined the bottom of the drawers with a light soft rubber sheeting, this I hope, is to stop any rubbing on the aluminium drawer base.
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Title: Re: jclures DIY crossover camper
Post by Derek on Jun 26th, 2018 at 8:57am
Draws look pretty neat.

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 26th, 2018 at 8:58am
They look good in the photo. :) :)

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 30th, 2018 at 2:42pm
Even though the kitchen drawer runners have a 225kg rating, I thought I should support the kitchen when out.
I wanted a simple leg which can be fitted when needed, and to be adjustable.
I had a swing down leg which was damaged, so after removing the damaged swing down part I have made a two stage adjustable leg.
I should be able to knead bread or do anything I want now on the kitchen bench without any movement at all.
Kitchen_Leg_01.jpg (235 KB | )
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Title: Re: jclures DIY crossover camper
Post by Derek on Jun 30th, 2018 at 3:14pm
Well that won’t move for sure. 

I know what you mean by “doing bread”.  I shake the whole motorhome when I am kneading.

I really do need to start working on perfecting no knead bread.  8-)

Title: Re: jclures DIY crossover camper
Post by jclures on Jul 6th, 2018 at 9:48pm
This week I have been reworking a few things. The first job to do is my compressor setup, I have had the Thor Air Compressor here for some time now ready to fit.
After testing I have decided to leave the compressor I have, and run the new one along side it. Each compressor has it's own airline to the tank with a check valve each as well. Before the new compressor it took around 5 minutes to pump the 9ltr tank to 120psi. I never timed it to 150psi which I want it to be set at.
With the two compressors now running with the tank empty it only took only a fraction over two minutes to shut off at 150psi.
The other job done was easy, I wanted a easy garbage bag setup. I went into BFC and brought a Croc Bin. All I needed to do is work out where I wanted to mount it, just need to take it off before breaking camp though.
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Title: Re: jclures DIY crossover camper
Post by jclures on Dec 20th, 2018 at 10:56am
Suspension upgrade

After several short trips with the camper, I am not happy with the suspension. I have for me, had too much role on the airbag suspension, so I have decided to redesign it.

I designed the chassis around these air bags, they were what I had to start with, if I can get it right they should be good off road, as there is around 9” travel.

I am moving the air bag closer to the wheel on each side by about 50mm. I am also adding a second set of air bags beside it. My thinking this should reduce the air pressure in them while travelling and make it more stable.

I was running around 145psi in the air bags Before,  with two each side this now should be halved or there about.  Also twice the surface area now for support although with the inside air bags this is diminished a little due to the leverage of the suspension. (I think)

I ended up building a new axle completely, it was easier this way. I took a leaf out of a build I saw on another trailer build on another forum, and welded my brackets to a second box section then welded it the to the axle.

I am also now using a 60 series Toyota rear sway bar as well, it is wide enough to have the link arms either side of the water tank, this alone should help as it is a lot stronger sway bar than I had before.
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Title: Re: jclures DIY crossover camper
Post by Derek on Dec 20th, 2018 at 10:59am
I know nothing about airbags but that looks like genius to me.

Title: Re: jclures DIY crossover camper
Post by jclures on Dec 20th, 2018 at 11:00am
I also had a look at the water tanks while they were  out. When I fitted them I brought water level senders which have given me a problems with the water leaking around the sender.
I think the tank wall thickness is to thick for the sender, so I have changed the way the sender is fitted.

I brought two screw covers used for boats, cut a hole in the top of the tanks and fitted the screw covers.
Then after cutting of the plug to the display unit, (I had to do this to get the nut washer and seal of the sender unit, it also let me trim of the excess length of wire)I then rearranged the washer, seal and lastly nut after fitting the sender in the tank. I then soldered the wiring to the plug back on.

There is no leaks now and the senders can't fall out.
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Title: Re: jclures DIY crossover camper
Post by jclures on Dec 20th, 2018 at 11:11am
As I have finished the new air bag design, it is time to get on with some fitting in the camper and the Nisota.
I wanted a camera on the rear of the camper, so I have gone to a Digital Wireless System. This was not the cheapest or the most expensive, but it should work for me.
The receiver monitor can run up to four cameras, which at present I only have two. One of these has been fitted to the rear of the camper and the other on my Nissan.
I an still to work out where to fit the monitor, as well as the phone, which is only used as a gps and mapping device.
I have also started putting the carpet in the camper under the bed, and on the battery box lid
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Title: Re: jclures DIY crossover camper
Post by TBF on Dec 20th, 2018 at 12:37pm
John, you are a genius.
That camper/van will be indestructible.


Title: Re: jclures DIY crossover camper
Post by jclures on Dec 20th, 2018 at 2:26pm
I am building this with a suck and see attitude, :) as I have no reference on how this might work.
But we took it for it first outing on the new Air bag system, and the pressure in the bags was reduced buy more than half to bring the camper to ride height. 60psi on the left side and 54psi on the right side.
The difference is due to the weight difference left and right sides.
I had a fellow camper follow me to give me feedback on the body role of the camper, he thought it now was very good. (he was a Police Man before retirement)
I am now back working on the inside of the camper as well as the 12v storage system.

Title: Re: jclures DIY crossover camper
Post by Chally on Dec 20th, 2018 at 4:59pm
Very impressive John!

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 20th, 2019 at 8:53am
Thanks Chally.
I brought these two batteries for the camper for its Christmas present, but before I fitted them I needed to get the wiring for them done as well.

With using my cpap machine, the more storage I have gives me more options travelling. I would like not to need any extra charging other than what is built into the camper and Nissan.
I already had two 90ah batteries fitted and with these two that will give me in total around 440ah. That should be around 4 day night trips even in wet weather with little or no solar input.
I had always planed on having four batteries, so the fitting them in was the easy bit.

After a bit of reading on charging battery banks I came up with my wiring diagram, but keeping it as modular as possible, letting me remove, replace or upgrade as needed. This also included the c/b boards which I had fitted but not finished.

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Title: Re: jclures DIY crossover camper
Post by shackles on Jan 20th, 2019 at 11:02am
John would that wireless camera set up be powerful enough for a caravan  ute setup without interference?
Did you get the 7" screen?

Title: Re: jclures DIY crossover camper
Post by jclures on Jan 20th, 2019 at 2:59pm
This is what I brought here , and it is a 5” monitor.

https://www.ebay.com.au/itm/2-4GHz-HD-Wireless-2-IR-CCD-Camera-5-Monitor-Reverse-Rear-View-Kit-Car-Truck/252348095243?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

The picture is very clear reversing, the one I have mounted on the camper seems to drop out and the come back. I talked to a fellow and he thought I have mounted the camera and antenna to close to the camper, the camper might be interfering in the signal.
I have yet to test this theory though.

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 7th, 2019 at 9:32am
With the rain we have had up here, it has given me time to finish and redo a few things.
Bonnie brought two outdoor chair cushions from K mart the other day, she then cut them down and fitted them into our seats in the camper.
Bonnie sewed Velcro onto the back of the cushions and I then fitted stick on into the camper to match, so the cushions should stay in place.
We never plan or using them to often but it does give us an option if we need to get inside out of bad weather.

I have not been happy with my pressure gauges for the suspension, they were a bit hard to see properly from where I built them into the side door area.
To fix it I lost half the shelf area, but it is now much easier to read. I also changer them to Viair gauges, 200psi on the tank and duel needle on the air bags.
At 50psi the camper is just sitting on the air bags and the front jockey wheel.
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Title: Re: jclures DIY crossover camper
Post by Derek on Feb 7th, 2019 at 10:57am
Looking good John.

Title: Re: jclures DIY crossover camper
Post by Chally on Feb 7th, 2019 at 12:08pm
Getting better and better!  [smiley=thumbsup.gif]

Title: Re: jclures DIY crossover camper
Post by tadpole on Feb 7th, 2019 at 2:55pm
Really impressive build mate

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 8th, 2019 at 10:52am
Thanks for the comments. We are hoping to get a few bits finished this weekend as well.
If we get a break in the weather next week we hope to go over to Tinaroo for the weekend, at Camp Barrabadeen.

Title: Re: jclures DIY crossover camper
Post by jclures on Feb 11th, 2019 at 7:48am
On the weekend Bonnie started making curtains for the camper, although with the first curtain done I am concerned it is moving away from being a camper.
I also finished the door vent. It had a bit of dust in the filter, from out to in, so I think I am going to need a pressure vent to give a positive pressure in the camper.
I had planed to do this before I head of on a dusty trip anyhow.
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Title: Re: jclures DIY crossover camper
Post by jclures on Mar 20th, 2019 at 8:42am
I have been tidying up the inside of my folding walls.
There is a gap along the top of the side walls created by the nylon blocks which I fitted..
These are there for two reasons. When the roof is down the weight of the roof rides on them. Also the thickness of the blocks controls the amount of squash on the outside roof seals.
The fix for the inside trim was easy, once I thought about it. All I used was 40x20x3mm aluminium angle riveted to the top.
I am also removing the latch in the centre of the wall for three draw bolts. This has made it easier for the end walls to swing up into place. As with only one arm I found it was hard to hold the ends of the wall out as I did this part of setting up.

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Title: Re: jclures DIY crossover camper
Post by Chally on Mar 20th, 2019 at 4:12pm
All the fine tuning takes time and a lot of thought John. Going well though.

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 21st, 2019 at 8:51am

Chally wrote on Mar 20th, 2019 at 4:12pm:
All the fine tuning takes time and a lot of thought John. Going well though.

I have found by getting out and using it helps, every time I go, I find another bit I would like to fix.
I also like to make look as good as I can given what my capabilities I have. :)

Title: Re: jclures DIY crossover camper
Post by Derek on Mar 21st, 2019 at 10:31am
I don’t think you ever stop playing with them John.

Even with our Motorhome it’s the same.  Always doing something or changing something.

I am currently changing our plumbing.  New water pump arrived the other day. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 21st, 2019 at 12:14pm
A man needs a few Hobbies, otherwise Bonnie will find me work she wants done. ;D

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 30th, 2019 at 8:23am
On the last couple of trips we have used our 45ltr fridge freezer, as a freezer for our frozen foods.
I have been doing this as a test, as if we go away for longer trips where I need to keep frozen food for a week or so I needed to know how the batteries will last with the solar we already had.
So after testing running the two fridges, and my cpap machine at night, I have now added a extra 160w solar panel into the system.
I might have to upgrade the solar regulator at some time as well as if all the panels were running at maximum output the unit might be the limiting factor.
I think something along these lines might be the go for me.

https://www.ebay.com.au/itm/EPEVER-10A-20A-30A-40A-MPPT-Solar-Charge-Controller-12V-24V-Auto-Negative-Ground/351931902011?var=621711396414


New Panel Fitted
160w_solar_panel.jpg (260 KB | )

Title: Re: jclures DIY crossover camper
Post by TBF on Oct 30th, 2019 at 8:38am
How many amph do you have in your battery storage John.?

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 30th, 2019 at 11:28pm
Aart from memory 400 amph, charged it floats a little over 13v, it normally will drop to around  12.8
(90%) over night, but back to full charge well before midday.
The extra fridge dropped it a bit more 12.6v over night and took longer to bring it back to full charge..

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 30th, 2019 at 11:30pm
I use this chart for my battery storage.
12-v-Battery-State-Of-Charge-website.jpg (26 KB | )

Title: Re: jclures DIY crossover camper
Post by TBF on Oct 31st, 2019 at 8:14am
Not seen that chart before.
Very handy.
Thanks John.

Title: Re: jclures DIY crossover camper
Post by Kevvie on Oct 31st, 2019 at 9:11am
Hi John
Yes also thanks for the chart.
your set up looking great
I have my caravan full time in the sun
Solar readings are usually showing between 13.2 - 13.8 :o

regards Kev..

Title: Re: jclures DIY crossover camper
Post by jclures on Oct 31st, 2019 at 10:51am
When charging I also get well over 13v, that is normal as far as I know.

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 1st, 2020 at 12:27pm
I have a 2.4GHz digital HD digital wireless rear view camera built onto the rear of the camper. It has not preformed as well as I would have liked, he picture freezes at times or just blacks out.

From what I have found out it could be because it is trying to transmit though the camper. It has a range of 100m but I think that to do this it has to be fitted line of sight.

I brought a 2.4GHz 3DBi booster antenna with a 3m cable, at a cost of $4.68 of ebay, thinking it is worth trying it to fix the problem.
For a test run I fitted it to the top of my high lift jack, ant it gave me a perfect picture, with good clarity.
Happy with that I have made a mount and attached the antenna on the back of the camper roof and routed the antenna cable back to the camera.
Digital_Wireless_System_03_001.jpg (232 KB | )
Digital_Wireless_System_004.jpg (230 KB | )
Digital_Wireless_System_005.jpg (241 KB | )

Title: Re: jclures DIY crossover camper
Post by Derek on Mar 1st, 2020 at 6:03pm
Very good John.

I installed a wireless camera in my old Colorado and had no end of issues with it.  Never thought of this.

Title: Re: jclures DIY crossover camper
Post by TBF on Mar 2nd, 2020 at 7:49am
You are clever John.

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 2nd, 2020 at 7:59am
I was not happy with the camera at all, this I thought if it worked, was worth trying.  My screen can run 4 cameras, which you can scroll through. This one runs of the parking lights, so I run with parking lights on and I can see who is behind.
I have one on the Nissan as a reversing camera. I would like a second one dedicated to backing up to the hitch, but at $140 for each camera it is on the still to do list.

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 2nd, 2020 at 8:52am
Derek on a side note, I received a notification of a new post, this is the first time I have received this for some time. Was it from the upgrade?

Title: Re: jclures DIY crossover camper
Post by Derek on Mar 2nd, 2020 at 9:39am

jclures wrote on Mar 2nd, 2020 at 8:52am:
Derek on a side note, I received a notification of a new post, this is the first time I have received this for some time. Was it from the upgrade?


Yes John, it seems to have fixed quite a bit. The old server had an issue with bigpond for some reason.  Cheers

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 16th, 2020 at 8:35am
Rear bar fitted
When I was first planing building the camper I planed on having a rear steel bumper bar, but I thought just fitting rubber bumpers will be good enough.
The problem with this was then, where to mount the swing down spare wheel. I have made a rear wheel carrier, but I found it heavy to lift and I could see no was to fit gas rams to assist.
I have now fitted a rear bar which in length  has added 200mm to the total length, but is no further out than the spare wheel anyhow.
Using some large weld on hinges I then modified the rear wheel carrier, and fitted two gas struts to assist in the lifting of the carrier.

New_rear_bar_01.jpg (240 KB | )
New_rear_bar_02.jpg (235 KB | )
New_rear_bar_03.jpg (233 KB | )
New_rear_bar_04.jpg (229 KB | )

Title: Re: jclures DIY crossover camper
Post by Chally on Mar 16th, 2020 at 11:24am
Very good John; it should be much more user friendly now.

Title: Re: jclures DIY crossover camper
Post by TBF on Mar 16th, 2020 at 2:00pm
John, have you got a current weight for the unit.
It must be getting heavy.
It will never fall apart.

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 16th, 2020 at 9:44pm
Chally it is much easier for me now, although I do not plan on changing tyres to often. :)
No Aart, I have not got a recent weight, but I will sooner or later, but I want a fully loaded weight, as it I was heading of on a longer trip.
Ball weight was when it tested it recently was 185kg, although that still depends what I have in the front storage area.
I think you are right though it will not fall apart  in a hurry.

Title: Re: jclures DIY crossover camper
Post by Chally on Mar 16th, 2020 at 10:09pm

jclures wrote on Mar 16th, 2020 at 9:44pm:
Chally it is much easier for me now, although I do not plan on changing tyres to often.


Nah it's a mugs game mate.  ;D

Title: Re: jclures DIY crossover camper
Post by Derek on Mar 17th, 2020 at 8:55am
I love the way it is evolving John.  This is a neat idea.  I keep my roadside assist number handy if I need to change a wheel on the Fiat.  ;D

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 18th, 2020 at 9:22am
Derek never thought of roadside assist, but they might not come to me sometimes due to where we are going, so I need it to work for me just in case. :)

Title: Re: jclures DIY crossover camper
Post by jclures on Mar 18th, 2020 at 9:24am
After a bit of thought I have started to fix the visible gap between the roof and camper, when the roof is down read to travel.

I first screwed and sealed a piece of 25mm x 3mm aluminium, and then a piece of 40mm  x 3mm aluminium. I have still left a gap between the roof and camper to allow for movement.
The front will look the same but I need to use 50mm to allow for the bolts for the actuators.

To me, it looks much better viably, and it keeps the seal in shape when down which should be better as well.


Before the new trim
after trim fitted
front still to do.
Roof_seal_gap_01.jpg (249 KB | 24 )
Roof_seal_gap_02.jpg (229 KB | 23 )
Roof_seal_gap_03.jpg (234 KB | 25 )
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Roof_seal_gap_05.jpg (235 KB | 28 )

Title: Re: jclures DIY crossover camper
Post by Chally on Mar 18th, 2020 at 5:52pm
Looks good John.

Title: Re: jclures DIY crossover camper
Post by jclures on May 5th, 2020 at 7:58am
With not being able, like everyone to get out camping, I have started doing things I wanted to anyhow. I brought a tap some time ago but have not got around to fitting it.
I wanted a tap for washing hands after the camper is hooked up and ready to go, so I have fitted it close to the hitch and on the inside of the chassis rails to protect it.

I also fitted a air outlet beside the water tap. I ended up by using a 1/2” tap mount to do the job. I cut off  the female and male 1/2” threads and then taping a 1/4” thread into the brass mount, and fitted the 1/4” fittings into it.

air_outlet_01.jpg (272 KB | 18 )
New_chassis_tap_01.jpg (270 KB | 21 )

Title: Re: jclures DIY crossover camper
Post by TBF on May 5th, 2020 at 8:47am
Is there a compressor in the van or is it to pump air in?
Can’t remember if you had airbags under the van

Title: Re: jclures DIY crossover camper
Post by jclures on May 5th, 2020 at 9:50am
Aart I have a compressor, which I am going to change for a Boss Unit, plus a 9ltr air tank.
As it has air suspension the air is a big part of the camper.

Title: Re: jclures DIY crossover camper
Post by Derek on May 5th, 2020 at 9:57am
Very neat indeed.

John, what do you expect to use the external air for??

Title: Re: jclures DIY crossover camper
Post by jclures on May 5th, 2020 at 10:30am
I just wanted it for air for servicing. It is quick to air up tyres when needed on the Nissan as well.

Title: Re: jclures DIY crossover camper
Post by Chally on May 5th, 2020 at 12:28pm
Good handy additions there John.

Title: Re: jclures DIY crossover camper
Post by jclures on May 5th, 2020 at 2:57pm
Chally I am slowly getting things done to make camping better for us.

In the front storage box I have now fitted my axe in a holder plus I also have fitted a spare actuator on the same frame. I can then if ever needed fit the spare if one fails.
The frame lifts out so I can service the water plumbing behind.
camper_axe_holder_01.jpg (266 KB | 18 )

Title: Re: jclures DIY crossover camper
Post by Chally on May 6th, 2020 at 10:56am

jclures wrote on May 5th, 2020 at 2:57pm:
Chally I am slowly getting things done to make camping better for us.


That is what is important mate. You certainly come up with some great ideas.

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 10th, 2020 at 8:06am
I have now fitted a TV in the camper. Thinking I might me able to use it, that is if there is any reception to watch some television while travelling around.
I had thought I might be doing a trips this year, it still might happen, but now waiting to see how things go.

The TV is a Medion 21.5 led 12v TV /DVD mounted to a Single arm TV bracket.

I also brought a  Topline TV Antenna which has a booster built in. Although I it uses 240v to 12v transformer for the injector, I will get a 12v injector so I do not need ac power at all.
I used a three sliding tent pole for the antenna mast which can stay mounted on the front storage box.

The antenna cable needed to go through the side folding wall so I used I a Fold Away Direct Connector so the antenna can be plugged directly to the TV,
As the TV is 12V I and also fitted a new 12V wall socket in with a extra USB outlet.
Topline_TV_Antenna.jpg (259 KB | 21 )
Fold_Away_Direct_Connector.jpg (224 KB | 19 )
12v_wall_socket_2_outlet.jpg (237 KB | 19 )
Medion_21_5_led_12v_TV_DVD_.jpg (239 KB | 18 )

Title: Re: jclures DIY crossover camper
Post by Derek on Jun 10th, 2020 at 9:11am
Nice one. 

Even if not used for TV the DVD players are very handy.  We often raid the DVD cupboard before heading off.

Nice to be tucked up inside on a wet winters night with the diesel heater running and a glass or two of raspberry cordial watching a movie.

We had satellite TV in our last caravan and found it to be pretty good.  If it wasn’t for weight restrictions would have put one on the motorhome.

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 10th, 2020 at 9:25am
I always said I did not want a TV, but I think it will come in use at times.
I actually do not even own a DVD, I have a lot of movies on our NAS so I can transfer to a Hard drive and use the on board USB socket if I want to.

Title: Re: jclures DIY crossover camper
Post by TBF on Jun 10th, 2020 at 2:50pm
We seldom watch TV on the road.
But as Derek said, on a wet day or evening it’s good.
I prefer the radio.

Title: Re: jclures DIY crossover camper
Post by Chally on Jun 11th, 2020 at 11:35am
We don't watch much TV either but it can come in handy. You have a good setup by the looks mate.

Title: Re: jclures DIY crossover camper
Post by jclures on Jun 11th, 2020 at 1:35pm
I will test it in the great out doors this weekend, we are going camping for a few night starting tonight. :)

Title: Re: jclures DIY crossover camper
Post by Chally on Jun 11th, 2020 at 5:19pm

jclures wrote on Jun 11th, 2020 at 1:35pm:
I will test it in the great out doors this weekend, we are going camping for a few night starting tonight. :)


Enjoy the time away. We were to head away Saturday for a couple of weeks but there is supposed to be some heavy rain over the weekend and where we were going is black soil so we will have to delay for a few days.

Title: Re: jclures DIY crossover camper
Post by jclures on Jul 30th, 2020 at 5:54pm
After a recant problem with the better half I had to pack the camper myself, and one of the hardest for me was the hitching up.
I decided maybe I needed to find a easier unit so I now have brought the McHitch automatic trailer coupler.
I had to do a few changes to fit it but hopefully it will be worth the change. I have done a couple of test coupling and it has worked very well.
McHitch_01.jpg (293 KB | 8 )
McHitch_02.jpg (279 KB | 8 )

Title: Re: jclures DIY crossover camper
Post by Kevvie on Jul 30th, 2020 at 7:39pm
Hi John
Looks pretty flash. Do you use a reversing camera?
I have a reversing camera on my Disco that points to the tow ball area. The only problem I have to press a button to stop the parking senors from beeping.
regards Kev.

Title: Re: jclures DIY crossover camper
Post by jclures on Jul 30th, 2020 at 8:18pm
Kev, I fitted a reversing camera on the Nissan some time ago.
Being a digital system it takes a few seconds to come on when in reverse, but I just wait until it comes on before trying to hook up.
Using the camera I just back up until the self lock applies on the hitch.
I will see how well it works as if need be I can run up to four cameras on my system.
I already have one on the rear of the camper linked in. When I turn on the parking light it comes on, so when on the road it helps to see who is behind..

Title: Re: jclures DIY crossover camper
Post by Kevvie on Jul 30th, 2020 at 8:26pm
John
Sounds good. I don't have any camera on the rear of the caravan.
I don't like seeing where I  have been  ;D ;D
Your camper looks pretty good I bet when blokes see it they want you to make one for them.
regards Kev  ;)

Title: Re: jclures DIY crossover camper
Post by Derek on Jul 30th, 2020 at 8:33pm
Good one John.  I was going to put one on my big caravan bit ended up swapping it for the motorhome.

Title: Re: jclures DIY crossover camper
Post by jclures on Jul 30th, 2020 at 8:59pm
I have had a few comments Kev, I have a sticker which is Built not bought as I have had some question it being home made.
Derek in hindsight I should have not used the tregg coupling, as it was always problematic for me to use with this camper.
sticker_upgrade.jpg (208 KB | 3 )

Title: Re: jclures DIY crossover camper
Post by Kevvie on Jul 30th, 2020 at 9:18pm
John
That is very good.
regards Kev

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 22nd, 2020 at 9:12pm
When in the early stages of building the camper I planed on water saving.
I bought a tap back then planing to divert the water back to the tank while waiting for the hot water and being able to divert during the shower as well.
I have now fitted the tap, and a diversion to the plumbing, we can now return the water before the shower head back to the tank.
I bought some chrome bits but found I could not fit them as hoped so for now 12mm push to connect fitting will do.
Alter Bonnie had a problem camping a few weeks ago, she has had difficulties getting into the camper, so it was time to fit my new eBay bling hand rail. I have wired the lights in but I doubt I will ever turn them on other than now.
Water_diversion_01.jpg (74 KB | 4 )
Bling_hand_rail_01.jpg (97 KB | 4 )

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 22nd, 2020 at 9:33pm
Have heard of a diverter before and often thought it a good idea.  I know we waste a lot of water waiting for the hot to come through.

Title: Re: jclures DIY crossover camper
Post by Kevvie on Aug 22nd, 2020 at 9:51pm
That is a pretty light there John.
Does your light  attract much wife life when you are out  camping?
regards Kev

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 23rd, 2020 at 8:40am
Derek I bought the tap to do this in the early planing, but never fitted it till now. I will tidy it up a bit after trying it out.
This mob now sell a kits to do the conversion, which would look better than my job, the in-wall is a tidy fit if it can be installed.

https://www.topargee.com.au/showermiser.html

Kev I needed the handle for safety the light is just bling, but I an tot to sure about wife life though. ;D

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 23rd, 2020 at 10:14am
Thanks John. 

Just looking at that I can see how simple it would be to fit it but getting the return pipe back to the tank side of the water pump could be a challenge as the shower is at the back of the the motorhome and the water tank is right up the front.

Time to put my creative cap on.

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 23rd, 2020 at 10:30am
I think they plumb it ti the inlet side of the water pump, not the tank.
I have plumbed it to the tank and the problem with this is when filling the tank it could flow through the shower diverter instead if the tap is set wrong. A simple one way valve is needed to fix this though.

Title: Re: jclures DIY crossover camper
Post by Derek on Aug 23rd, 2020 at 10:41am
I recently put a one way valve between my pump and water tank to stop back flow when connected to town water so a simple job to put a t-piece in below that.

I like the simplicity of the JG connectors and piping.

Title: Re: jclures DIY crossover camper
Post by jclures on Aug 23rd, 2020 at 10:58am
They make plumbing easy, although I have bought most of my fittings on line for convenience as local suppliers are limited. The price is better as well.
I did use blue and red tubing but I have found using the black thick wall tubing is better to use.

Title: Re: jclures DIY crossover camper
Post by Chally on Aug 23rd, 2020 at 11:02am
That diverter is a good idea; at present we just put a container under the shower head to collect the cold water prior to the hot coming through.

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