Author Topic: OverLanding Camper Build (Read 75053 times)

Flyin6 · « **Reply #400 on:** November 25, 2019, 04:19:20 PM »

Quote from: JR on November 25, 2019, 01:36:06 PM

What does the blond see in the first picture?

Why mount the junction box in the open, or will it be covered?

What angled lights are those?

Blonde: Who knows!

Fuse box out in the open where I want it to be, easy to see and check

Flyin6 · « **Reply #401 on:** November 25, 2019, 08:52:19 PM »

That butt end joint turned out strong and flat

Flyin6 · « **Reply #402 on:** November 25, 2019, 08:59:03 PM »

First longitudinal piece added to the left side. Top sides are spaced 3/4" from the inside rail to allow for fabric thickness top and bottom

Flyin6 · « **Reply #403 on:** November 25, 2019, 08:59:57 PM »

Keeping the 45 degree angle theme going

Flyin6 · « **Reply #404 on:** November 25, 2019, 09:00:39 PM »

Then the back plate was added

Flyin6 · « **Reply #405 on:** November 25, 2019, 09:01:42 PM »

The right side longeron is in place and here is the first of several parts of the front edge

Flyin6 · « **Reply #406 on:** November 25, 2019, 09:02:41 PM »

I ran out of plywood and had to source my ready stack of cedar from the farm, planed to a proper harness

Flyin6 · « **Reply #407 on:** November 25, 2019, 09:04:26 PM »

Next I added a vertical 3 1/2" piece of SYP, then reinforced the backside with a 45 degree piece of fir glued on all sides

Flyin6 · « **Reply #408 on:** November 25, 2019, 09:05:18 PM »

This single stiffener really did the job of tightening up the whole front

Flyin6 · « **Reply #409 on:** November 25, 2019, 09:05:57 PM »

And here it is with the top hat in position

Flyin6 · « **Reply #410 on:** November 25, 2019, 09:07:16 PM »

And tonight the youngest preranger was awarded a varsity patch for football as a 9th grader! He actually won his varsity letter in wrestling as an eight grader.

Nate · « **Reply #411 on:** November 25, 2019, 09:16:47 PM »

Thats awesome!

JR · « **Reply #412 on:** November 25, 2019, 09:31:06 PM »

Letter as a 8th/9th grader in Varsity is awesome.

Work looks good on the camper.

Bigdave_185 · « **Reply #413 on:** November 26, 2019, 12:08:07 AM »

This is the boy who has missed a bunch with the hospital visits also right?

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Flyin6 · « **Reply #414 on:** November 26, 2019, 10:33:45 AM »

Quote from: Bigdave_185 on November 26, 2019, 12:08:07 AM

This is the boy who has missed a bunch with the hospital visits also right?

Sent from my iPhone using Tapatalk

Yep, had to work extra hard to make up for time lost to sickness
Notice the West point hoodie?
Has wanted to go to WP for years and become a US Army Infantry Officer and Ranger. In fact he has no other plans.
He got a "B" in algebra and came to talk to me about how he had to pull his GPA up!
And, No, Bobby, he has no interest in flying...Just wants to be a grunt.
Maybe not my child...dunno...#confused#crazy#can'tthinkstraight#WTH

Nate · « **Reply #415 on:** November 26, 2019, 12:17:08 PM »

The fact that you just dropped all of those hash tags.....

Bigdave_185 · « **Reply #416 on:** November 26, 2019, 12:47:02 PM »

#notinstagram lol

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Flyin6 · « **Reply #417 on:** November 26, 2019, 07:38:19 PM »

In preparation to mount the rear hinged lifting device, I doubled up the top rail to 1.5" thickness

Flyin6 · « **Reply #418 on:** November 26, 2019, 07:40:01 PM »

Then installed the piano hinge onto the lower edge. This hinge will soon be attached to the lower part to that doubled aft rail

Flyin6 · « **Reply #419 on:** November 26, 2019, 07:41:46 PM »

Here it is completely attached to the aft wall top rail and shown in the fully extended position. Just imagine the top being attached to the upper end and you get an idea for the height I'll have inside

Flyin6 · « **Reply #420 on:** November 26, 2019, 07:43:55 PM »

When raised it has this gap beneath. I think I'll look at the design and come up with a way to lock it out in the erected position just incase one of the curious grand-girls decide to pull on it while doing some curtain climbin'

Flyin6 · « **Reply #421 on:** November 26, 2019, 07:47:07 PM »

So I needed a way to actually assemble the hinge to the top, but because of the way the hinge needs to be attached I could only do it if I was inverted in a parallel universe. Heisenberg device is in the shop for a time flux gate calibration so I just decided to create something that would attach to the hinge and then attach to the hinge. I decided on a number of #10 X 24 screws and threaded inserts into a piece of ply. The holes on the top of the hinge is where the screws go to capture the bottom hinged up piece

Flyin6 · « **Reply #422 on:** November 26, 2019, 07:48:15 PM »

Another view of all that business:

Flyin6 · « **Reply #423 on:** November 26, 2019, 07:49:18 PM »

How that works:

Flyin6 · « **Reply #424 on:** November 26, 2019, 07:50:55 PM »

It was easiest to just bolt the whole thing to the bulkhead in the top, snug up a few screws, then slide the bulkhead/rib into the top frame

Flyin6 · « **Reply #425 on:** November 26, 2019, 07:52:17 PM »

Once I had it down in the top outside framing I attached it with 10- 1.5" blocks with glue only

Flyin6 · « **Reply #426 on:** November 26, 2019, 07:53:30 PM »

A bunch of clamps get used but none were hurt or abused in the making of tonight's thread installment.

Flyin6 · « **Reply #427 on:** November 26, 2019, 07:55:12 PM »

The door latch for the fold-out kitchen is done:

I may do a little more work on it...dunno.

Kintuckee proud!

Bigdave_185 · « **Reply #428 on:** November 26, 2019, 09:04:45 PM »

Quote from: Flyin6 on November 26, 2019, 07:43:55 PM

When raised it has this gap beneath. I think I'll look at the design and come up with a way to lock it out in the erected position just incase one of the curious grand-girls decide to pull on it while doing some curtain climbin'

I would think a piece of rubber ( think bike tire tube) if stapled or glued onto both edges could be flexible enough to move, keep water or what not out, keep fingers from being smashed

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Flyin6 · « **Reply #429 on:** November 29, 2019, 05:42:49 PM »

Been a busy couple of days

Thanksgiving, wood choppin' then pickin' up things

So, wasn't an abundance of time to get much done.

But I did get some things done

I decided to lighten up the hinge apparatus thing used to raise the roof. I started by punching a 5" hole in it

Flyin6 · « **Reply #430 on:** November 29, 2019, 05:43:35 PM »

Then I punched a whole bunch more into it

Flyin6 · « **Reply #431 on:** November 29, 2019, 05:44:02 PM »

Saving this much weight:

Flyin6 · « **Reply #432 on:** November 29, 2019, 05:46:46 PM »

It actually made some noticeable difference. I did not mount it because I have not completely laid out how it will mount. I need to take care that it is removable and does not block the entrance when the top is lowered.

I did cut out the banding for the top of the chassis that will form the rest of the lip and drip rail that the top will rest on. It will eventually have a foam tape layer sealing the tpo to the chassis

Flyin6 · « **Reply #433 on:** November 29, 2019, 05:57:36 PM »

But wait, there's more!

It is about time to put the thing on the ground, so I scored some furniture dollies from HFT which were on sale today for $10.99 ea. That isn't bad for a carpet covered hardwood rectangle 30" long with four casters. I picked up five.

I also ordered all the door latches for the various doors located just about everywhere. I'll cut them in, then build sturdy mounts for the top latches, 4 ea. which I also ordered.

Add to that, I started listing out the Electrical plan for the interior. I thought I'd start there, then draw boxes where everything gets located, then start routing and pulling wires.

The electrical plan will include:

Overhead Fan 12VDC
2 ea. Overhead lights, LED 12VDC
Reading lamp, right 12VDC
Reading lamp left, 12VDC
Water pump, 12VDC
Electrical outlet Left 115VAC
Electrical outlet right 115VAC
Cigarette lighter outlet 12VDC
2 ea. USB ports for recharging 5VDC
On demand (gas) H2O heater 12VDC
exterior outlet in pantry 115VAC
Exterior outlet in Kitchen 115VAC
outlet located in electrical compartment 115VAC
Tail Lights (trailer to vehicle harness)
2 ea. Exterior lights, LED 12VDC
door/entry light, LED 12VDC
Exterior shower light 12VDC

Flyin6 · « **Reply #434 on:** November 29, 2019, 07:06:27 PM »

And now I have a lot of the electrical stuff ordered

But I could use some advice on how to set that all up

I will have two 6VDC deep cycle batteries in series to make 12VDC. That will supply all the 12 volt requirements.

I will have a rectifier to provide the 115VAC stuff, but I will also have the 2000W generator.

On that point, I am not sure if I just have the gen power a battery charger, or maybe figure out how to have it feed the AC side of things in tandem with the rectifier. Again, not real clear how to set that all up

Additionally I will have a solar panel which will recharge the batteries, and finally, a shore power cable, make it 20 amps, 115VAC.

Some things will obviously run strictly off of AC, such as the coffee maker and AC unit, and some things strictly off of DC such as the water pump and LED lights.

I'll have to self educate some on electrical theory and application to get that sorted, but in a macro sense, that is where I am going.

JR · « **Reply #435 on:** November 29, 2019, 07:24:38 PM »

Have you thought about going with a Lifo battery at all? Rated for 3k discharges and you can fully discharge them without damage.

Most are made with cells inside the case so you can build your own for less. Just have to keep from freezing and about twice the price pf AGM.

https://www.ebay.com/itm/ICCNexergy-Lithium-Iron-Phosphate-Battery-07-56178-002-12-8V/202754880272?hash=item2f3521f310:g:ptUAAOSwrHRdUImC

https://youtu.be/L43bArxyszU

Flyin6 · « **Reply #436 on:** December 01, 2019, 07:50:23 PM »

Got the trim piece installed. I cut it in around the taillights and glued it on every surface it touched

Flyin6 · « **Reply #437 on:** December 01, 2019, 07:51:45 PM »

Then I made up the shower door guard. I clamped and glued it on a board covered with parchment paper and got zero sticking

Flyin6 · « **Reply #438 on:** December 01, 2019, 07:53:04 PM »

It came out as strong as expected. I roughed up the back side with a belt sander and #36 grit then glued/clamped it in place

Flyin6 · « **Reply #439 on:** December 01, 2019, 07:54:45 PM »

Next I got after the roof, starting to build in the top panel support structure. I had to taper the first section from 1.25" out to 2" to clear the lifting hinge

Flyin6 · « **Reply #440 on:** December 01, 2019, 07:56:08 PM »

Then added a section section which thickened up to 3.5" installed height

Flyin6 · « **Reply #441 on:** December 01, 2019, 07:58:49 PM »

All of this is very rigid and the top is actually screwed to the chassis during this part of the build with spacer blocks to keep everything fitting well and playing together.

Next up was another "Rafter" if you will to create a space for the fan

Flyin6 · « **Reply #442 on:** December 01, 2019, 08:00:23 PM »

This is where the seam of the roof sheeting will fall so I created a wide "Nailer" ledge which I will also box in for some added strength at mid span

Flyin6 · « **Reply #443 on:** December 01, 2019, 08:01:57 PM »

The fan is now roughed in as it were. Not far from starting some wiring

Flyin6 · « **Reply #444 on:** December 01, 2019, 08:02:53 PM »

I cut this board twice and its still too short!

So I glued some back onto the end to see if I can make some magic!

JR · « **Reply #445 on:** December 02, 2019, 07:05:08 PM »

How heavy is the top so far (est) ?

Flyin6 · « **Reply #446 on:** December 02, 2019, 09:31:45 PM »

Quote from: JR on December 02, 2019, 07:05:08 PM

How heavy is the top so far (est) ?

Its light so far

As you will see with tonight's installment it lifts and tilts. In the end it will have 4 ea gas cylinders assisting the up, so it shouldn't be much to worry about. The SYP framing is very light. The fan is light, about the only thing of substance is the 3/4" plywood sides.

Flyin6 · « **Reply #447 on:** December 02, 2019, 09:33:40 PM »

In these pics, I have removed the screws holding the top to the body so that I could get at an area to install a hinge. The up effort is not much to speak of, maybe 30 pounds ish

Flyin6 · « **Reply #448 on:** December 02, 2019, 09:36:43 PM »

Attempt #1, I screwed the hinge to the upper bulkhead, but I did not like the angle, so I added another piece of ply to the vertical rib to strengthen it and push the hinge aft just a tad for better alignment

Key here is getting the hinge to hang in such a way that it does not interfere with access through the door

Flyin6 · « **Reply #449 on:** December 02, 2019, 09:37:51 PM »

And here it is hanging in the proper position, and I have attached the top piece (Which is on the bottom in this pic)