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jclures DIY crossover camper (Read 41568 times)
 
Mar 31st, 2016 at 10:23pm

jclures   Offline
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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.

...

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.

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Reply #1 - Mar 31st, 2016 at 10:24pm

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I have now cut all the A frame steel and have started capping and cutting the angles needed in the chassis design.

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

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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
 
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Reply #2 - Apr 2nd, 2016 at 9:12pm

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I am hoping to save weight where I can, hopefully without taking away the strength in the chassis.

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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.

...

how to work on the other side rail.
 
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Reply #3 - Apr 2nd, 2016 at 9:20pm

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I am fascinated by all this John.  Thanks for sharing.  Looking forward to seeing it all come to life.
 

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Reply #4 - Apr 2nd, 2016 at 9:54pm

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How long do you think it will take to build John?
 

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Reply #5 - Apr 2nd, 2016 at 10:04pm

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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.
 
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Reply #6 - Apr 3rd, 2016 at 7:16am

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Thanks for the report John.. I shall be following your progress with much interest.

Aart
 

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Reply #7 - Apr 3rd, 2016 at 8:04am

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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.
 

Its not burnt. Just really well done.
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Reply #8 - Apr 3rd, 2016 at 10:54am

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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

 
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Reply #9 - Apr 3rd, 2016 at 3:47pm

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Wow. I love the camper trailer.  I'd read about the nisota somewhere else before. Keep up the good work.
 

Its not burnt. Just really well done.
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Reply #10 - Apr 3rd, 2016 at 8:00pm

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Enjoying seeing the build.

Jeff
 
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Reply #11 - Apr 10th, 2016 at 9:45am

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I have finished the two a frame sections, and welded the front brace. I will fit the plate for the hitch later on.

...

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.


...

I hope I can get this welded today and fitted to the chassis.
 
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Reply #12 - Apr 10th, 2016 at 6:44pm

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Good seeing the progress.

Jeff
 
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Reply #13 - Apr 10th, 2016 at 9:07pm

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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.


...

...

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.

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The front chassis is now together.

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

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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.
 
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Reply #14 - Apr 10th, 2016 at 9:08pm

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It is slow progress I can tell you Jeff.
 
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Reply #15 - Apr 10th, 2016 at 9:15pm

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It certainly is but it will be all worth it when finished.

Jeff
 
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Reply #16 - Apr 11th, 2016 at 8:13pm

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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.

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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.
 
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Reply #17 - Apr 11th, 2016 at 10:24pm

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How big are the tanks John?

Aart
 

...
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Reply #18 - Apr 11th, 2016 at 10:28pm

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80 litre tanks from Dunn & Watson.
 
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Reply #19 - Apr 12th, 2016 at 4:46pm

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Jc you are doing an amazing job looking forward to seeing your progress
 

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Reply #20 - Apr 12th, 2016 at 8:33pm

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


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

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Reply #21 - Apr 12th, 2016 at 8:50pm

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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.
 
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Reply #22 - Apr 14th, 2016 at 9:04pm

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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.

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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.

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I think I will gusset the plate as well, the holes are for the two hammer locks to hold on the safety chains.
 
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Reply #23 - Apr 14th, 2016 at 9:05pm

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Looking very neat John.
 

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Reply #24 - Apr 18th, 2016 at 8:14pm

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Thanks Derek, I have a saying, I might not be quick but I am rough enough. Smiley
 
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Reply #25 - Apr 18th, 2016 at 8:18pm

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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.

...

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.

...

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.

...
 
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Reply #26 - Apr 19th, 2016 at 9:45am

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It actually looks much bigger than the dimensions in one of your previous posts.
 

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Reply #27 - Apr 19th, 2016 at 10:52am

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Derek this should give you an idea of the finished chassis. 5.550m long excluding hitch and bumperbar and 1.950m wide.

...

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.
 
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Reply #28 - Apr 19th, 2016 at 10:56am

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Very, very impressive jc.

Enjoying watching your journey.
 

...
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Reply #29 - Apr 19th, 2016 at 1:54pm

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Coming along nicely JC. We hope to see you in about 4 weeks time. Do you think you will have it finished by then?  Grin Grin
 

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Reply #30 - Apr 19th, 2016 at 2:07pm

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No trouble. Wink Smiley
 
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Reply #31 - Apr 19th, 2016 at 4:07pm

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Very interesting seeing it taking shape John.

Jeff
 
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Reply #32 - Apr 19th, 2016 at 8:44pm

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Jeff I am enjoying it taking shape too. Smiley Smiley
 
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Reply #33 - Apr 19th, 2016 at 9:01pm

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I have been collecting some of the parts for this build for some time.

Speedy Wheels 16 x 8”  28mm offset.

...

Air Bags

...

actuators

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12” heavy duty brakes, Land Cruiser wheel bearings.

...

I have a few other goodies to fit as I go as well.
 
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Reply #34 - Apr 19th, 2016 at 9:05pm

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.
 

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Reply #35 - Apr 21st, 2016 at 9:14pm

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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.

...

I have also finished the rear end of the chassis.


...

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.

 
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Reply #36 - Apr 21st, 2016 at 9:37pm

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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. Smiley

Jeff
 
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Reply #37 - Apr 22nd, 2016 at 8:20am

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Seems like it's coming along nicely jc bloody amazing job your doing
 

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Reply #38 - Apr 23rd, 2016 at 6:51pm

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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
 

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Reply #39 - May 2nd, 2016 at 12:27pm

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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.
 
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Reply #40 - May 2nd, 2016 at 1:58pm

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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.

...
 
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Reply #41 - May 2nd, 2016 at 8:18pm

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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. Roll Eyes

...

...

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.
 
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Reply #42 - May 2nd, 2016 at 10:51pm

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Take it easy jc it'll still be there when your ready
Fantastic sometimes takes a little longer
We got time mate
 

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Reply #43 - May 12th, 2016 at 9:57am

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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.

...

...

...

Once centered I will weld them in, also plug welding the ends of the stubs as well.
 
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Reply #44 - May 12th, 2016 at 12:31pm

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Very interesting to see all this being done.

Jeff
 
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Reply #45 - May 12th, 2016 at 10:41pm

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Looking good so far
 
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Reply #46 - May 16th, 2016 at 7:47am

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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.

...

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.

...


Now it is ready for me to start to fit the arms in place.
 
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Reply #47 - May 16th, 2016 at 8:47pm

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This arrived in todays mail, I had thought about another tank but this one was a good price I thought.

...

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

...
 
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Reply #48 - May 18th, 2016 at 9:41pm

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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.

...

Once I fit the bottom trailing arms I will know if my drawing are right regarding the air bag fitment.
 
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Reply #49 - May 19th, 2016 at 8:20am

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It is fascinating seeing this all come together
 

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Reply #50 - May 19th, 2016 at 10:53pm

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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 Smiley
 

...
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Reply #51 - May 20th, 2016 at 6:23am

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Wow thats one big air tank for two bags
how are you planning to fill and maintain pressure in it
 
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Reply #52 - May 20th, 2016 at 8:44pm

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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.
 
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Reply #53 - May 21st, 2016 at 7:50am

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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
 
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Reply #54 - May 21st, 2016 at 9:58am

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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.
 
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Reply #55 - May 21st, 2016 at 11:15am

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What type of height control valve are you planding on using?
 
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Reply #56 - May 21st, 2016 at 3:17pm

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Reply #57 - May 24th, 2016 at 7:25am

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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.

...

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.

...

...

I can now finish welding the brackets on and think about fitting the shock absorbers.
 
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Reply #58 - May 24th, 2016 at 9:41am

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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?
 
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Reply #59 - May 25th, 2016 at 6:34am

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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.
 
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Reply #60 - May 29th, 2016 at 9:33pm

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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.

...

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

...

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.
 
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Reply #61 - Jun 6th, 2016 at 8:02am

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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.

...

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.

...

...

...

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.
 
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Reply #62 - Jun 6th, 2016 at 10:47am

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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
 
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Reply #63 - Jun 6th, 2016 at 10:52am

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Jeff they are 6mm rivnuts in the cross member to hold the water tanks.
 
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Reply #64 - Jun 6th, 2016 at 12:42pm

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You can see why caravan manufacturers stick to the same chassis setup for lots of different models.

Just amazing seeing all this go together.
 

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Reply #65 - Jun 6th, 2016 at 2:24pm

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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
 
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Reply #66 - Jun 6th, 2016 at 2:54pm

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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-T...

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.
 
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Reply #67 - Jun 6th, 2016 at 7:40pm

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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 ?
 
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Reply #68 - Jun 6th, 2016 at 9:10pm

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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.
 
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Reply #69 - Jul 22nd, 2016 at 8:26pm

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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.

...

...

...

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.
 
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Reply #70 - Jul 22nd, 2016 at 9:06pm

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Looking good John.
 

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Reply #71 - Jul 22nd, 2016 at 9:50pm

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Looks very impressive 
 
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Reply #72 - Jul 22nd, 2016 at 10:54pm

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Lookin' good.

Jeff
 
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Reply #73 - Jul 28th, 2016 at 10:05pm

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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.

...

...
 
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Reply #74 - Jul 28th, 2016 at 10:11pm

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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.  Huh
 
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Reply #75 - Jul 28th, 2016 at 10:28pm

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Slowly but surely John. Cheers
 

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Reply #76 - Jul 29th, 2016 at 5:32pm

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John, remember Rome wasn't built in one day either I am sure that you will get there
 
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Reply #77 - Jul 29th, 2016 at 8:19pm

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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.

...


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.

...
 
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Reply #78 - Aug 4th, 2016 at 7:34am

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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.

...

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.

...

Back leg.

...

Front leg

...

Now I can get back to the brakes.
 
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Reply #79 - Aug 5th, 2016 at 8:58pm

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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.

...

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

...


...

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

...

Now I need to finish of a few other jobs so I can turn it over and start on the main camper.
 
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Reply #80 - Aug 7th, 2016 at 1:50pm

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Excellent; very neat JC.

Jeff
 
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Reply #81 - Aug 10th, 2016 at 6:57pm

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I get even more amazed every time I look at this thread.  You are doing a fantastic job John
 

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Reply #82 - Aug 10th, 2016 at 7:41pm

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I've seen John's planning and drawings for the xover.
The man's a genius.

Aart
 

...
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Reply #83 - Aug 10th, 2016 at 8:03pm

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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.
 

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Reply #84 - Aug 10th, 2016 at 10:25pm

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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

 
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Reply #85 - Aug 15th, 2016 at 6:42pm

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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.
 
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Reply #86 - Aug 15th, 2016 at 7:31pm

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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.

...

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.

...

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..

...

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.

...

I will now remove all the bits of the chassis and paint it, ready to turn over for the last time I hope.
 
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Reply #87 - Aug 15th, 2016 at 7:42pm

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Taking shape more an more John.  Looks great.
 

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Reply #88 - Aug 15th, 2016 at 8:29pm

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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.

...

...

Ready to start to put it together and turn it over for the next stage.
 
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Reply #89 - Aug 15th, 2016 at 8:33pm

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Impressive John!

Jeff
 
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Reply #90 - Aug 15th, 2016 at 8:35pm

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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   Cheesy

 

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Reply #91 - Aug 23rd, 2016 at 8:16am

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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.

...

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

The chassis now finished.

...


...


...


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.
 
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Reply #92 - Aug 23rd, 2016 at 8:24am

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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.
 

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Reply #93 - Aug 23rd, 2016 at 10:22am

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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.
 
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Reply #94 - Aug 23rd, 2016 at 10:23am

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Very impressive John!

Jeff
 
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Reply #95 - Aug 28th, 2016 at 8:34pm

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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.

...

...
 
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Reply #96 - Aug 28th, 2016 at 8:44pm

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It certainly is taking shape mate. Keep the updates coming. Smiley

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Reply #97 - Sep 4th, 2016 at 2:23pm

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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.

...

...

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

...

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

...

I do need to make a temporary frame to build the roof to but that should not take long, then onto the roof framing.
 
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Reply #98 - Sep 4th, 2016 at 6:29pm

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Wow John, that is amazing.  It is even starting to look like a small off road caravan.
 

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Reply #99 - Sep 4th, 2016 at 7:09pm

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That caravan isn't going to fall apart John.
Got to be way stronger than anything else on the market.

Aart
 

...
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Reply #100 - Sep 4th, 2016 at 7:33pm

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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. Grin
 

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Reply #101 - Sep 5th, 2016 at 8:17am

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Derek it is taking shape, it is good to see the ideas I had in my head are now being able to see. Smiley
Aart, no I don't think it will fall apart any time soon. Cheesy
I have no idea Undecided 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.
 
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Reply #102 - Sep 5th, 2016 at 7:07pm

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Nice work JC...its really starting to  come together now. Smiley
 
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Reply #103 - Sep 6th, 2016 at 8:14pm

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Looking the business now jc
Can't wait to see the finished project  Smiley
 

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Reply #104 - Sep 8th, 2016 at 7:51am

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I have now settled on the design of my hopefully lifting roof.

...

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.

...

The bed frame started.

...
 
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Reply #105 - Sep 8th, 2016 at 7:56am

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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.
 
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Reply #106 - Sep 11th, 2016 at 8:48pm

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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.

...


...
 
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Reply #107 - Sep 13th, 2016 at 7:20am

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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.

...

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.

...

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.

...

...
 
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Reply #108 - Sep 13th, 2016 at 7:46am

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What size is that grey water tank John.

Aart
 

...
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Reply #109 - Sep 13th, 2016 at 7:56am

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40l from ebay Aart
http://www.ebay.com.au/itm/252418695048?_trksid=p2057872.m2749.l2649&ssPageName=...
It should cover me if and when i need it.
 
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Reply #110 - Sep 13th, 2016 at 8:02am

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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.
 

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Reply #111 - Sep 13th, 2016 at 3:06pm

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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=...
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
 

...
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Reply #112 - Sep 13th, 2016 at 3:32pm

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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.
 

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Reply #113 - Sep 13th, 2016 at 6:48pm

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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
 

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Reply #114 - Sep 13th, 2016 at 9:53pm

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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
 
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Reply #115 - Sep 14th, 2016 at 7:43am

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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. Smiley
 
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Reply #116 - Sep 14th, 2016 at 11:31am

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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.
 

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Reply #117 - Sep 15th, 2016 at 3:39pm

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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=...
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
 

...
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Reply #118 - Sep 15th, 2016 at 6:22pm

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I am thinking of using 2 x square 20lt plastic containers. Is that passable?
 

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Reply #119 - Sep 15th, 2016 at 6:39pm

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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 Smiley
 

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Reply #120 - Sep 21st, 2016 at 8:29pm

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The tube slides arrived, so now I cam think about starting the sliders for the actuators.

...

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


...

...

One done, now to work on mounting the actuator to the slider.
 
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Reply #121 - Oct 13th, 2016 at 9:44am

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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.

...


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.


...


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.

...

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

Weather seal gap

...

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.
 
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Reply #122 - Dec 23rd, 2016 at 11:53pm

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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.

...

...

roof mounting point.

...

looking down through the  main shell rear double wall frame.

...

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. 
 
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Reply #123 - Dec 24th, 2016 at 9:56am

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Welcome home John.


Aart
 

...
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Reply #124 - Dec 25th, 2016 at 4:50am

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Good to see you back working on it.  Looking good.
 

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Reply #125 - Dec 25th, 2016 at 8:19am

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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.
 
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Reply #126 - Dec 25th, 2016 at 9:18am

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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.
 

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Reply #127 - Jan 30th, 2017 at 10:45am

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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.

...

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

...

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.

...

...

They are ready now to bend into there final shape.
 
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Reply #128 - Jan 30th, 2017 at 11:46am

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Looking good John
 

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Reply #129 - Jan 30th, 2017 at 9:11pm

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Derek I hope I can make a bit of progress for a while now, things had slowed down to a crawl.
 
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Reply #130 - Jan 30th, 2017 at 9:26pm

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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.

...
 
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Reply #131 - Jan 30th, 2017 at 9:35pm

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John

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

Thanks
 

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Reply #132 - Jan 30th, 2017 at 9:56pm

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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.
 
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Reply #133 - Feb 2nd, 2017 at 10:57pm

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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.

...

...

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.

...

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.
 
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Reply #134 - Feb 3rd, 2017 at 7:17am

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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) Grin Grin
 

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Reply #135 - Feb 9th, 2017 at 10:25pm

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You could be right. Smiley
 
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Reply #136 - Feb 9th, 2017 at 10:25pm

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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.

...

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.

...

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.

...

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

...

...

folded out with the window in position.

...

I still now need to make the top half of the door, but I feel I am now making progress.
 
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Reply #137 - Feb 13th, 2017 at 10:13pm

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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. Roll Eyes

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.

...

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

...
 
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Reply #138 - Feb 14th, 2017 at 11:21am

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Coming together nicely.
 

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Reply #139 - Mar 18th, 2017 at 10:37pm

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I have not been able to get on with much recently for other reasons, but I have now got most of the flooring down.

...

front storage area floor.

...

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.

...

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

...

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.
 
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Reply #140 - Mar 18th, 2017 at 10:44pm

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Very impressive John.
 

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Reply #141 - Mar 19th, 2017 at 1:32pm

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Whewwww that's a big job to take on.
Gotta admire your patience and skills to be able to build something like that. Smiley
SBB
 
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Reply #142 - Mar 19th, 2017 at 8:14pm

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Looking good JC.

Aart
 

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Reply #143 - Mar 26th, 2017 at 10:00am

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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.

...

...

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.

...

...

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.
 
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Reply #144 - May 11th, 2017 at 9:13pm

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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.

...

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

...

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

...

Now I can get onto the inside sheeting on this wall.
 
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Reply #145 - May 11th, 2017 at 10:07pm

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Looking good John.

Were you keeping those old batteries just for the job Smiley
 

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Reply #146 - May 12th, 2017 at 9:20am

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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. Smiley
 
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Reply #147 - May 15th, 2017 at 8:25am

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The first of the folding walls is now made, only three more to go. Smiley

...

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.
 
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Reply #148 - Jul 23rd, 2017 at 7:39am

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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.
 
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Reply #149 - Aug 1st, 2017 at 8:26pm

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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.
 
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Reply #150 - Aug 1st, 2017 at 10:06pm

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Thanks for the update John.  Looking good.l
 

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Reply #151 - Aug 10th, 2017 at 9:31pm

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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.
 
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Reply #152 - Aug 20th, 2017 at 7:58pm

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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.
 

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Reply #153 - Aug 21st, 2017 at 7:26am

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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.
 
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Reply #154 - Aug 21st, 2017 at 9:28pm

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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.
 
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Reply #155 - Sep 12th, 2017 at 8:48pm

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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.
 
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Reply #156 - Sep 12th, 2017 at 9:22pm

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Ahhhhh, the technical bits.

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

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Reply #157 - Sep 13th, 2017 at 6:50am

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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-ea...

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.
 
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Reply #158 - Sep 13th, 2017 at 8:04am

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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.
 

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Reply #159 - Sep 15th, 2017 at 7:59am

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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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Reply #160 - Sep 16th, 2017 at 8:55am

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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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Reply #161 - Sep 16th, 2017 at 9:07am

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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.
 

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Reply #162 - Sep 16th, 2017 at 12:02pm

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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-micr...

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-gro...

I think that should cover most problems with water, other than going the full reverse osmoosis systems.
 
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Reply #163 - Sep 16th, 2017 at 1:47pm

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All looks good.
 

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Reply #164 - Oct 5th, 2017 at 8:04am

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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.
 
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Reply #165 - Oct 5th, 2017 at 9:04am

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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.
 

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Reply #166 - Oct 5th, 2017 at 9:21am

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I might have to ask a moderator for help then.
 
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Reply #167 - Oct 5th, 2017 at 11:58am

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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  Smiley.
 

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Reply #168 - Oct 5th, 2017 at 9:31pm

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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.

...
 

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Reply #169 - Oct 5th, 2017 at 9:41pm

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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.
 
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Reply #170 - Oct 5th, 2017 at 9:58pm

Derek   Offline
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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.
 

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Reply #171 - Oct 6th, 2017 at 10:25pm

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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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Reply #172 - Oct 18th, 2017 at 8:05am

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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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Reply #173 - Oct 18th, 2017 at 8:08am

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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.
 
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Reply #174 - Oct 18th, 2017 at 8:12am

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I have now fitted the new air bags, along with the new paddle valves and things are looking up, airbags that is,  Smiley as they are still up sitting at 75psi.

The back looks a little untidy.

Along with the air lines.
 
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Reply #175 - Oct 18th, 2017 at 9:47am

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Looks like it is coming together nicely John.  Very good customer relations there I must say.
 

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Reply #176 - Oct 19th, 2017 at 9:59am

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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. Smiley
 
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Reply #177 - Oct 19th, 2017 at 10:01am

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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.
 
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Reply #178 - Oct 19th, 2017 at 10:07am

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Very nice 
Ever considered  going into the private camper order construction business
 
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Reply #179 - Oct 19th, 2017 at 10:13am

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Looking good John.

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

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Reply #180 - Oct 19th, 2017 at 10:42am

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Bonnie has said, definitely not. Grin
 
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Reply #181 - Oct 19th, 2017 at 10:48am

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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.
 
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Reply #182 - Oct 20th, 2017 at 9:36am

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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_01.jpg
roof_off_02.jpg (138 KB | )
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Reply #183 - Nov 5th, 2017 at 8:14am

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