Author Topic: OverLanding Camper Build (Read 75082 times)

Flyin6 · « **Reply #1000 on:** March 02, 2020, 09:59:25 PM »

If you've ever seen a vintage Alaskan pop up slide in, I think I have captured that classic look pretty effectively.

Looking in from the right window to give an idea of the expansive room in there for a (sort of) teardrop

Flyin6 · « **Reply #1001 on:** March 02, 2020, 10:04:02 PM »

So, things are moving right along. The awning will be arrive in a day or two.

I am putting my order together for the steel and aluminum, but now breaking that down into two orders. All the small stuff in one order, then the frame pieces in another.

The electric linear actuators are inbound with a tracking number, two 36" travel with a 225 lb capacity each. I will pick up the square tubing which will be used to construct a compound semi-scissors linkage that will finish off the top construction. Well, after I secure the EPDM with some 1" aluminum angle, that is...

Bigdave_185 · « **Reply #1002 on:** March 03, 2020, 09:24:51 AM »

That’s a whole lot of brushing Don. Looks good!!

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Flyin6 · « **Reply #1003 on:** March 03, 2020, 12:32:49 PM »

Thanks

Priority is to the big stuff now that almost all of the interior and little stuff is completed.

Get the rubber on the top pinned down
Get the lift mechanism built
Get the underside coated
Get the frame built
Get the two parts married up
Make the fabric part to connect the top and body
Go drive many. many miles ;-)))

Sammconn · « **Reply #1004 on:** March 03, 2020, 07:20:31 PM »

Looking real good chief.
That cedar sure popped with the finish!

Flyin6 · « **Reply #1005 on:** March 03, 2020, 09:33:56 PM »

Quote from: Sammconn on March 03, 2020, 07:20:31 PM

Looking real good chief.
That cedar sure popped with the finish!

Sure did!

I was waiting on doing the roof until I decided on what material to use. My son helped me, saying he thought it would look good with the same cedar, so I have several packs of the stuff here already waiting to go in.

Things are starting to consolidate. The aluminum and steel for the top and lifting mechanism is all in, the awning arrives tomorrow or the next day, and I am about to order the steel for the frame. I didn't want it to be sitting around very long so I have held off.

Today I got the bottom mostly coated with two coats of that harbor freight bedliner, which, is actually the best of that type of product I can find. I used about a half dozen of the air activated epoxy bed liner products and this stuff from HF is a standout. My bumpers that I sprayed last summer still look great, black and shiny and not falling apart.

Now that big assembly bench is under the camper and covering a big spot that will have to be coated. The plan is to move that tomorrow and get the primer, then the paint on. Hopefully with that working out, the rest of the belly will be coated and ready for a frame by weeks end.

rpar86 · « **Reply #1006 on:** March 04, 2020, 12:27:33 AM »

Couldn’t you have just done the bottom when you put it on it’s side to get it out the door? That is still the plan right?

Flyin6 · « **Reply #1007 on:** March 04, 2020, 10:03:08 AM »

Quote from: rpar86 on March 04, 2020, 12:27:33 AM

Couldn’t you have just done the bottom when you put it on it’s side to get it out the door? That is still the plan right?

Ryan, I could have done that. but I chose to do it this way.
Another factor is, I have to remove a steel post supporting an I-beam which supports the main floor. I figure I can pop in a temporary couple of posts to support the beam while I do the move, which I plan to only take a few hours. I would not be comfortable watching my house settle into the basement. And that darned post narrows things up just enough to prevent an aerial rotation with it being there.

dave945 · « **Reply #1008 on:** March 04, 2020, 10:40:20 AM »

Don, when you get ready to migrate the camper to the outside, let me know if you need a hand. I’m about ready for a foray outside the house and I think my wife is about ready for me to get out for a bit too.

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rpar86 · « **Reply #1009 on:** March 04, 2020, 06:35:08 PM »

10-4 chief. I vaguely recall mention of the steel post once before.

Flyin6 · « **Reply #1010 on:** March 04, 2020, 08:36:13 PM »

Quote from: dave945 on March 04, 2020, 10:40:20 AM

Don, when you get ready to migrate the camper to the outside, let me know if you need a hand. I’m about ready for a foray outside the house and I think my wife is about ready for me to get out for a bit too.

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Dave,
I was thinking just today that we need to go get a cup of joe together

Flyin6 · « **Reply #1011 on:** March 04, 2020, 08:40:07 PM »

I am just liking this stuff. Chinaman super muck numba 21. Or Harbor Freight bed liner for the record. It is the consistency of warm tar and dries on the super quick. I mean by the time you finish rolling the first coat, just go right ahead with the second.

Bring plenty of rollers though. Because it cures so quickly, it forms pills on the end of the roller which is rubbed off onto your otherwise smooth surface where it forms spongy balls. I was able to wipe them off fairly easily so no big deal really

Flyin6 · « **Reply #1012 on:** March 04, 2020, 08:42:03 PM »

30 min of layin' on your back and undergoing an ethnicity change from white to black and I was done. Later I moved the supports and started the process all over

Flyin6 · « **Reply #1013 on:** March 04, 2020, 08:43:14 PM »

I got the unfinished sections all the way through the second coat of epoxy, so tomorrow I get to expose everyone to hazardous fumes yet again.

Flyin6 · « **Reply #1014 on:** March 04, 2020, 08:44:31 PM »

And, Dave, I found some space to coat the cedar boards before cutting and installing!

Flyin6 · « **Reply #1015 on:** March 04, 2020, 08:46:54 PM »

Fixed the area of peeling and got a couple coats around the filter storage opening

I figured out why that paint lifted below the kitchenette. I had some red grease from the old hinge unit that was probably smeared around by a sander disc, compromising the paints ability to adhere

Flyin6 · « **Reply #1016 on:** March 04, 2020, 08:47:55 PM »

Here is the folding shower mount loosely installed as a test fit

Flyin6 · « **Reply #1017 on:** March 04, 2020, 08:49:20 PM »

Then I pulled the wire for the overhead LED interior lights. Now I'm ready to finish insulating and install the roof cedar panels

Flyin6 · « **Reply #1018 on:** March 04, 2020, 08:50:15 PM »

Then I finished wiring the last of the lights, the electrical compartment lamp

Flyin6 · « **Reply #1019 on:** March 04, 2020, 08:51:38 PM »

I applied a coat of bed liner on top of the triple thick spare tire mount. The black area gets a sheet of steel with the actual tire wheel mount welded to it. THis surface will never see the light of day

Bigdave_185 · « **Reply #1020 on:** March 05, 2020, 09:26:18 AM »

When insulating the roof area, I seen the insulation doesn’t come flush with the studs. Air gap or going to fill it up more?

I have been wondering which direction would the air gap best be served? Inside the trailer or outside? Before rotomold coolers there was simply a air gap and plastic. The super eco homes will build up air gaps between the siding and the outside sheeting.
Just curious on others and your thoughts.

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Flyin6 · « **Reply #1021 on:** March 05, 2020, 12:49:33 PM »

Quote from: Bigdave_185 on March 05, 2020, 09:26:18 AM

When insulating the roof area, I seen the insulation doesn’t come flush with the studs. Air gap or going to fill it up more?

I have been wondering which direction would the air gap best be served? Inside the trailer or outside? Before rotomold coolers there was simply a air gap and plastic. The super eco homes will build up air gaps between the siding and the outside sheeting.
Just curious on others and your thoughts.

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I'm not putting that much thought into it. My plan was to shove the extruded insulating panel in there, then cover with the cedar, then fill the cavity with foam insulation to get the R-value up and the noise level down
You may see that happen this very day.

Flyin6 · « **Reply #1022 on:** March 06, 2020, 01:41:22 PM »

Here's the almost flush mount LED interior lights I chose. These burn at a cooler temp producing a softer yellowish light. They fit nicely in a 2.25" hole

Flyin6 · « **Reply #1023 on:** March 06, 2020, 01:42:43 PM »

The first two installed in the aft overhead structure

Flyin6 · « **Reply #1024 on:** March 06, 2020, 01:43:37 PM »

This is making things go much quicker. It's running the 18 gage brads

Flyin6 · « **Reply #1025 on:** March 06, 2020, 01:44:14 PM »

More of the overhead insulation stuffed in all the vacant rectangles

Flyin6 · « **Reply #1026 on:** March 06, 2020, 01:45:21 PM »

And, a bit of a screw-up here. I ran the second piece of plank without cutting in for the connecting cable. I'll get to redo that as a consequence!

Flyin6 · « **Reply #1027 on:** March 06, 2020, 01:46:08 PM »

I'm liking how this looks inside. Makes me want to go for a pine box casket some day...

JR · « **Reply #1028 on:** March 06, 2020, 02:24:59 PM »

Like those lights, amazon?

Flyin6 · « **Reply #1029 on:** March 06, 2020, 09:20:05 PM »

Quote from: JR on March 06, 2020, 02:24:59 PM

Like those lights, amazon?

Yes/Yes

Bigdave_185 · « **Reply #1030 on:** March 06, 2020, 09:20:52 PM »

Let’s turn off The shop lights and leave on those pod lights.

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Flyin6 · « **Reply #1031 on:** March 06, 2020, 09:21:21 PM »

After cutting a slot to move the cable outboard, here is the fix to the added surgery

Flyin6 · « **Reply #1032 on:** March 06, 2020, 09:21:59 PM »

Quote from: Bigdave_185 on March 06, 2020, 09:20:52 PM

Let’s turn off The shop lights and leave on those pod lights.

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OK, good idea...hadn't thought of that. I'll get a shot tomorrow

Flyin6 · « **Reply #1033 on:** March 06, 2020, 09:23:46 PM »

The panelling is somewhat slow due to the many steps. Once a "Block" is covered up, I have to go back and fill the cavity up with the expanding foam.

Flyin6 · « **Reply #1034 on:** March 06, 2020, 09:27:34 PM »

Two more lights installed overhead of the door. The small round one switches on with three other ones positioned at the four corners

Flyin6 · « **Reply #1035 on:** March 06, 2020, 09:29:13 PM »

six long boards from finishing the main stretch of the roof assembly

Flyin6 · « **Reply #1036 on:** March 06, 2020, 09:30:48 PM »

Way back when I was assembling the roof structure, I had to figure in the clearance for the roof panel to the lifting/support hinge. Look how close that came out:

Flyin6 · « **Reply #1037 on:** March 06, 2020, 09:31:51 PM »

I have the roof tilted at the moment. I've not seen the odd resulting angle

JR · « **Reply #1038 on:** March 07, 2020, 03:33:51 AM »

Still waiting to see how you vent that water heater?

Flyin6 · « **Reply #1039 on:** March 07, 2020, 07:41:10 PM »

Quote from: JR on March 07, 2020, 03:33:51 AM

Still waiting to see how you vent that water heater?

I always put things off that I don't want to do!

Flyin6 · « **Reply #1040 on:** March 07, 2020, 07:43:24 PM »

Dave asked for pics of the lights, so I turned off the shop lights, and it has no windows so I got to real dark, real quick

The shots show various configurations of interior lights on and off

Flyin6 · « **Reply #1041 on:** March 07, 2020, 07:44:06 PM »

And the exterior lights that will illuminate beneath the awning

Flyin6 · « **Reply #1042 on:** March 07, 2020, 07:44:45 PM »

Here's the electrical compartment

Flyin6 · « **Reply #1043 on:** March 07, 2020, 07:46:03 PM »

The fold down kitchenette

And the pantry. I couldn't open the door after repositioning the thing for the belly painting

Flyin6 · « **Reply #1044 on:** March 07, 2020, 07:46:52 PM »

I had a bit of expanding foam find a pathway to freedom!

Flyin6 · « **Reply #1045 on:** March 07, 2020, 07:48:09 PM »

I finished the paneling of the main part of the roof. I will still need to tuck some in the rear and the extreme front

Flyin6 · « **Reply #1046 on:** March 07, 2020, 07:50:17 PM »

Next I glued the EPDM rubber to the underside of the roof, the secured the underside with some 1" X .125 aluminum angle

Flyin6 · « **Reply #1047 on:** March 07, 2020, 07:51:35 PM »

That really cleaned things up!

Flyin6 · « **Reply #1048 on:** March 07, 2020, 07:53:09 PM »

The front piece finished that chore and sets me up to start fabbing the lift mechanism

Flyin6 · « **Reply #1049 on:** March 07, 2020, 07:55:43 PM »

The 900 mm (36" stroke) linear actuators showed up finally. They will lift 225 lbs ea. So with 450 lbs total lift they should lift the roof, but I am thinking I need to incorporate a couple of gas lift cylinders to allow the actuators to run at optimum speed