Author Topic: OverLanding Camper Build (Read 75040 times)

Flyin6 · « **Reply #150 on:** October 19, 2019, 09:39:49 PM »

The cabinet unit will fit in a corner on a 45 degree angle. Here it is going together, built from more cabinet grade 3/4"

Flyin6 · « **Reply #151 on:** October 19, 2019, 09:41:05 PM »

Fitted with the removable front facia to allow me to access the AC unit should I need to

Flyin6 · « **Reply #152 on:** October 19, 2019, 09:41:38 PM »

Some stiffening added to the back side

Flyin6 · « **Reply #153 on:** October 19, 2019, 09:42:15 PM »

Inner structure

Flyin6 · « **Reply #154 on:** October 19, 2019, 09:44:02 PM »

The thing will attach to the back, a side, and a top panel. Just before adding that top panel, I added some blocking to screw/glue to

Bigdave_185 · « **Reply #155 on:** October 20, 2019, 01:51:39 AM »

Does it require a fresh air vent?

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TexasRedNeck · « **Reply #156 on:** October 20, 2019, 08:33:25 AM »

It should penetrate the outer wall and the back should be open to the outside and a water drain to the outside as well for condensate

Is that unit have heat as well so you have heat and ac?

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Flyin6 · « **Reply #157 on:** October 20, 2019, 12:01:29 PM »

Quote from: Bigdave_185 on October 20, 2019, 01:51:39 AM

Does it require a fresh air vent?

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Yes

Flyin6 · « **Reply #158 on:** October 20, 2019, 12:02:26 PM »

Quote from: TexasRedNeck on October 20, 2019, 08:33:25 AM

It should penetrate the outer wall and the back should be open to the outside and a water drain to the outside as well for condensate

Is that unit have heat as well so you have heat and ac?

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It will. That part of the corner will get opened up and be covered with a vented/louvred panel(s). They are actually due to arrive tomorrow.

No heat, just AC

Heater will be a propane catalytic unit mounted on the front wall

wyorunner · « **Reply #159 on:** October 20, 2019, 12:52:47 PM »

Quote from: Flyin6 on October 20, 2019, 12:02:26 PM

Quote from: TexasRedNeck on October 20, 2019, 08:33:25 AM
It should penetrate the outer wall and the back should be open to the outside and a water drain to the outside as well for condensate

Is that unit have heat as well so you have heat and ac?

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It will. That part of the corner will get opened up and be covered with a vented/louvred panel(s). They are actually due to arrive tomorrow.

No heat, just AC

Heater will be a propane catalytic unit mounted on the front wall

Have you bought your heater yet? Seems there is a wide variety out there, When brother Was building his 4wheel camper look alike He ended up with the wave 3, but after this season he is considering changing it next year.

He did what your doing, but with aluminum frame and siding, for a tacoMa sized pop up slide in camper. Modeled from the company 4Wheel Campers.

Flyin6 · « **Reply #160 on:** October 20, 2019, 06:14:54 PM »

T, I do have a heater sort of picked out. Going with the one Wes used in his build. He was out in it over the winter on the KAT with temps hovering near zero. He said it stayed toasty warm inside the whole time, and those things are thrifty on gas consumption...Unlike that Suburban!!!!!!!

Flyin6 · « **Reply #161 on:** October 20, 2019, 06:19:23 PM »

Here is the shelf piece that is going in the back.
Several reasons:

Can sleep a kid (Or a grunt if he is a smaller grunt)
Is a storage place
Beefs up the structure back there
The water tank below
Spare tire on the back
Hinge point for the pop up top
Acts as a top for the multiple cabinets all going in there
Serves as a barrier for the top and discourages one from going back there

Flyin6 · « **Reply #162 on:** October 20, 2019, 06:20:50 PM »

Then I cut some of it away and rounded the edges

Flyin6 · « **Reply #163 on:** October 20, 2019, 06:21:28 PM »

Still a decent size

Flyin6 · « **Reply #164 on:** October 20, 2019, 06:22:21 PM »

It attaches to several panels and in several planes

Flyin6 · « **Reply #165 on:** October 20, 2019, 06:24:45 PM »

With taking care I can pre-drill the holes and get a 2" #8 screw in there on 8" centers to provide plenty of strength even without the glue. But after the glue dries, I could actually pull all the screws out, and I have pulled some, but are leaving most of them in place.

Now I have a ceiling to attach the AC enclosure to

Flyin6 · « **Reply #166 on:** October 20, 2019, 06:26:14 PM »

The AC cabinet was cured or dried or whatever that stuff did, so it was time to attach it. Using one of my Japanese coping saws, I cut out for the stiffener and flush out strips

Flyin6 · « **Reply #167 on:** October 20, 2019, 06:26:49 PM »

It will install in this corner:

Flyin6 · « **Reply #168 on:** October 20, 2019, 06:28:32 PM »

Now for some reason that corner coupled with my limited flexibility in some directions conspired to make getting at the screws an act of sino-masochism! Ya, it hurt!

Flyin6 · « **Reply #169 on:** October 20, 2019, 06:30:41 PM »

And yes, I didn't notice that I got the right wing in off flush

And the darned glue is all set up

ERRRRRRR

Gotta figure out what to do. Not a simple rip out and redo. That wood is like it grew that way with that strange expanding glue stuff!

So, I'll just sit on it a bit and decide how to fix that

TexasRedNeck · « **Reply #170 on:** October 20, 2019, 08:38:48 PM »

any particular logic to why you put the AC in the corner instead of cutting a hole to the exterior and having the unit hang out about 3 inches to clear the drain?

Flyin6 · « **Reply #171 on:** October 21, 2019, 10:23:53 AM »

Quote from: TexasRedNeck on October 20, 2019, 08:38:48 PM

any particular logic to why you put the AC in the corner instead of cutting a hole to the exterior and having the unit hang out about 3 inches to clear the drain?

Actually, I do have an answer to that

Watching videos of Wess "Wheeling" with an XJ pulling his adventure camper of the same DNA, he was negotiating a section of the KAT. The rut or cut or ditch or whatever it was driving through was deeper than the top of the camper and off camber. The view narrowed to focus on the clearance between the side of the camper and the rocky side of the ground. That clearance got down to an inch or two. Anything sticking out 2"-3" would have been scraping along.

I do actually have some parts of the camper that protrude an inch beyond the sides, but they are "armored" to some extent as you will see in a couple of days.

TexasRedNeck · « **Reply #172 on:** October 22, 2019, 06:25:03 AM »

:thumb

CM sir

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KensAuto · « **Reply #173 on:** October 22, 2019, 01:00:24 PM »

I was with Tex on that one. Will refrain from further comments until after proof of concept.

Flyin6 · « **Reply #174 on:** October 22, 2019, 01:51:31 PM »

All right then!

Copy: CM

Wilco

Flyin6 · « **Reply #175 on:** October 23, 2019, 12:34:57 PM »

Pressing ever onward, it is time to cut out and place the outdoor kitchen cabinet into the side. It will go here:

Flyin6 · « **Reply #176 on:** October 23, 2019, 12:36:53 PM »

And this stack of confederates will be that cabinet

Flyin6 · « **Reply #177 on:** October 23, 2019, 12:38:30 PM »

I'm keeping it to 8" depth, which is a compromise, as is nearly everything in a limited space build like this one because I do not want to take up interior space if I can help from doing so

Flyin6 · « **Reply #178 on:** October 23, 2019, 12:39:15 PM »

An essential tool for making square corners

Flyin6 · « **Reply #179 on:** October 23, 2019, 12:40:38 PM »

The inside surface remains at 3/4" thickness because this cabinet is actually structural, joining the wheel well area to the top and the side

Flyin6 · « **Reply #180 on:** October 23, 2019, 12:41:22 PM »

All glued up and lookin for a home

Flyin6 · « **Reply #181 on:** October 23, 2019, 12:42:38 PM »

The fit was really nice, pretty tight on all sides and took some tapping to move it in there

Flyin6 · « **Reply #182 on:** October 23, 2019, 12:45:52 PM »

The plan is to allow the box to protrude 1" out of the side, then provide these 45 degree pieces to both make the fitment stronger and to provide a "ricochet" surface should I encounter "wait-a-minute" brush or drag on a vertical surface

Flyin6 · « **Reply #183 on:** October 23, 2019, 12:48:06 PM »

A view if the inside stikin-in part ;-)

Remember that 3/4" of foam insulation, then some interior panel will still flush out the wall, so the "IF" (Invasiveness factor) (double ;-)) ain't soo bad!

Flyin6 · « **Reply #184 on:** October 23, 2019, 12:50:48 PM »

I think I mistakenly mis-spoke earlier when I said the kitchenette shelf/cabinet thing would tie in the wheel well and the top and sides.

It is actually the pantry box/shelf dubisary-thing-ah-ma-jig that does that. To be cut into the side like the box we just saw, it started like this:

Flyin6 · « **Reply #185 on:** October 23, 2019, 12:52:30 PM »

And ended up like this after first smearing that weird gorilla glue between my fingers.

It's all good, I needed some layers of useless skin yanked off so I could nurse some wounds over the next day or so.

JR · « **Reply #186 on:** October 23, 2019, 01:38:07 PM »

For all that gluing I think gloves are needed with GG. Black fingers look nasty!

Maybe the gussets should be solid wood, might be stronger and easy to find make?

Looks good, how about some overall pics and a glimpse of the frame idea?

Bigdave_185 · « **Reply #187 on:** October 23, 2019, 07:38:54 PM »

I would like to see a glue stress test.

Butt two ends together with glue only. Than two in a t shape

Than go ahead and take a photo of the aftermath of you breaking the joint please.

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Bear9350 · « **Reply #188 on:** October 23, 2019, 08:59:33 PM »

I had an internship at a company that made laminate beams for covered bridges. We were gluing 2x6 and 2x8 lumber together to make very large beams. I would cut the laminated beams up and break the joints in shear using a hydraulic press. Then grade the joint based on how much of the wood failed compared to the glue. Most of the failure was always in the wood and not the glue.

Flyin6 · « **Reply #189 on:** October 23, 2019, 09:16:48 PM »

I think it would be an interesting test, os I'll do it tomorrow

I can tell you that the joints are absolutely solid. There is no deflection anywhere panels are joined. Now with this ongoing reinforcing the overall box is getting stronger by the day. Just a monocoque construction, I would be super surprised if I had any failure anywhere in this structure. I am really taking my time on this one and so far results are good.

TexasRedNeck · « **Reply #190 on:** October 23, 2019, 09:18:21 PM »

Estimated weight to date? 7,000lb.....

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Flyin6 · « **Reply #191 on:** October 23, 2019, 09:20:13 PM »

I cut some sections of cedar wood into right triangle cross section. I then cut that on a 45 so it met flush at the corners. This is the ramp surface to deflect things and additionally add to the total gluing surface holding the cabinet in place. Look carefully and you can see the glue expanding into the crevices

Flyin6 · « **Reply #192 on:** October 23, 2019, 09:25:40 PM »

Quote from: TexasRedNeck on October 23, 2019, 09:18:21 PM

Estimated weight to date? 7,000lb.....

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In the hundreds of pounds pounds, I'd guess

But we can do better than that

An average sheet of 3/4" is 84 pounds

At the point I am at tonight, (Not represented by tonights pics) I have cut up 12 sheets of ply. From that I'd estimate I have 3-4 sheets of waste, so call it 8.5 sheets for a total of 714 pounds

TexasRedNeck · « **Reply #193 on:** October 23, 2019, 09:26:40 PM »

Just chops bustin in the virtual O Club, Chief!

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Flyin6 · « **Reply #194 on:** October 23, 2019, 09:27:43 PM »

Looking messy, but it is installed, screwed and glued

Although it looks like a mess in this pic, after sanding it looks great...That's where I am currently in the assembly

Flyin6 · « **Reply #195 on:** October 23, 2019, 09:28:36 PM »

Quote from: TexasRedNeck on October 23, 2019, 09:26:40 PM

Just chops bustin in the virtual O Club, Chief!

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I knew

But it was a good place to get some factual information out there

Flyin6 · « **Reply #196 on:** October 23, 2019, 09:35:25 PM »

Next, I cut the access for the pantry cabinet

Flyin6 · « **Reply #197 on:** October 23, 2019, 09:37:26 PM »

And attached that in the same manner

Flyin6 · « **Reply #198 on:** October 23, 2019, 09:38:26 PM »

Inside view showing minimal intrusion of wood molecules

Flyin6 · « **Reply #199 on:** October 23, 2019, 09:41:19 PM »

^^^ Hmmm, that was weird. I put the pic in upright and it went sideways!

Here you can see the glue doing its expansion thing between the wheel well and the cabinet bottom. It creates a multi piece "I" beam construction which made that region of the box as solid as could be.