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Offline JR

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Re: OverLanding Camper Build
« Reply #50 on: October 07, 2019, 09:22:16 PM »
I would use a polyurethane based clear coat for the sealer. Will remain flexible and soak in really well and EASY to spray.

Just me, but I would gusset the 90* joints, glued and screwed or not. That's in theme with the plate on the but joints and would coast no room at all.

I would fiberglass coat the outside with a light cloth for the best finish and undercoating the bottom. Otherwise the wood grain will come through.
« Last Edit: October 07, 2019, 09:25:46 PM by JR »
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Offline stlaser

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Re: OverLanding Camper Build
« Reply #51 on: October 08, 2019, 06:36:02 AM »
I wouldn’t use garage floor epoxy for wood, find a suitable finish for wood. I like the raptor liner idea
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Re: OverLanding Camper Build
« Reply #52 on: October 08, 2019, 07:23:25 AM »
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

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Offline JR

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Re: OverLanding Camper Build
« Reply #53 on: October 08, 2019, 10:59:28 AM »
Can't believe they cut out those windows and doors on it.
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Offline Atkinsmatt

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Re: OverLanding Camper Build
« Reply #54 on: October 08, 2019, 11:38:01 AM »
I put the rustoleum garage floor paint down and the 4 wheelers and SxS are parked in there regularly.  It hasn't held up and I wouldn't recommend it.  I used the etching that came with it.  It was not new concrete.
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #55 on: October 08, 2019, 11:53:04 AM »
I would use a polyurethane based clear coat for the sealer. Will remain flexible and soak in really well and EASY to spray.

Just me, but I would gusset the 90* joints, glued and screwed or not. That's in theme with the plate on the but joints and would coast no room at all.

I would fiberglass coat the outside with a light cloth for the best finish and undercoating the bottom. Otherwise the wood grain will come through.
It already has gussets, just not shown yet, you'll see

And polyurethane, hadn't thought of that. So you're suggesting poly in lieu of kilz as the base/primer coat?
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Offline JR

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Re: OverLanding Camper Build
« Reply #56 on: October 08, 2019, 01:28:31 PM »
I do like Kilz for wood, but thinking long term it may be better on the outside. I use poly for wood that shows and it works well.

If you glass the outside I would not seal the wood, the resin will do that. If you use resin, go epoxy and not poly. Epoxy remains flexible and doesn't crack like poly does.
« Last Edit: October 08, 2019, 09:07:55 PM by JR »
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #57 on: October 08, 2019, 08:29:05 PM »
Getting a little out in front of myself here, but I will fill all voids and screw holes with bondo, then sand it all smooth. I was planning on a double coat of Kilz, then allow that to dry.

I would go over that with an orbital sander using 150 grit, then go over with another coat of kilz. I may shoot an good sealer paint over that without sanding or maybe allow to dry and sand again. Not sure, but I want to avoid any wood grain showing up. I'd like the thing to be partially glossy which will require a pretty flat panel, and half Raptor in the same color as the Suburban, but again, undecided on that at the moment.
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #58 on: October 08, 2019, 08:30:43 PM »
Next I cut in the door. I purchased a quality unit measuring 26" X 36" which was the largest I found for a teardrop type camper
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #59 on: October 08, 2019, 09:12:12 PM »
I stuck a small 12" X 24" window in the drivers side also
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #60 on: October 08, 2019, 09:12:57 PM »
This panel is about ready to get attached
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #61 on: October 08, 2019, 09:23:53 PM »
At this point I started adding in 1" X 3/4"gussets held in place with screws until the glue dries. THose really stiffened the thing up
« Last Edit: October 08, 2019, 09:24:36 PM by Flyin6 »
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #62 on: October 08, 2019, 09:25:39 PM »
And the other side is attached
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Offline JR

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Re: OverLanding Camper Build
« Reply #63 on: October 09, 2019, 12:21:24 AM »
Are the wheel wells going to be metal of some type?
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Offline Bigdave_185

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Re: OverLanding Camper Build
« Reply #64 on: October 09, 2019, 06:59:05 AM »
Next to me up here is a wells cargo trailer facility,  they will sell replacement material for say my enclosed trailer in rolls, why not cover you exterior like thAt or source the flat Fiberglas panels they use for these large RVs running around.


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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #65 on: October 09, 2019, 03:33:00 PM »
Are the wheel wells going to be metal of some type?
You will see in tonight's installment my friend!
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #66 on: October 09, 2019, 03:34:08 PM »
Next to me up here is a wells cargo trailer facility,  they will sell replacement material for say my enclosed trailer in rolls, why not cover you exterior like thAt or source the flat Fiberglas panels they use for these large RVs running around.


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I just really like working with wood, and after coating it with several layers, it is really a composite panel anyway.
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #67 on: October 09, 2019, 07:10:28 PM »
Lets answer JR's question right now

The wheel wells are also made from the same 3/4" ABX as the rest of the body. I plan for the entire body to be a monocoque construction with internal stiffeners and bracing that would allow the box to be a stand alone unit. Starting with that strength, bolting it onto a stiff steel frame should allow for a long leak free life (I hope!)
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #68 on: October 09, 2019, 07:11:55 PM »
Here both sides are boxed in. There was a wee bit of cutting all those angles to make for large flat glueing surfaces
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #69 on: October 09, 2019, 07:13:09 PM »
Next up I added the front angle plate that sweeps back at a 45 degree angle for one foot of lateral distance

I opted to add in a gusset to the long seam to allow for robust strength, not the usual kind of girly-man strength ;-))
« Last Edit: October 09, 2019, 07:15:36 PM by Flyin6 »
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #70 on: October 09, 2019, 07:14:35 PM »
I cut the top and bottom panels on a 22.5 degree miter that matched up so well, I almost just left it in glue alone...but didn't
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Offline JR

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Re: OverLanding Camper Build
« Reply #71 on: October 09, 2019, 07:47:11 PM »
Just keep the rangers away with the Sawzall!
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Offline TexasRedNeck

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Re: OverLanding Camper Build
« Reply #72 on: October 09, 2019, 08:42:41 PM »
That design almost screams for a tilt roof panel. 


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Offline Bigdave_185

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Re: OverLanding Camper Build
« Reply #73 on: October 09, 2019, 09:29:16 PM »
Sawzall? I was thinking heating element or lighter lol.


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Re: OverLanding Camper Build
« Reply #74 on: October 09, 2019, 11:42:59 PM »
I have mixed feelings about the raptor liner. Not sure how good it would stay stuck on primered, sealed, finely sanded wood. It would suck to have that stuff start peeling off in sheets (like it is on my aluminum ranger bed).
...plus you need to spray clear, or paint on it to keep it from fading (like my bumper, and I think yours also).
I'd fiberglass the whole thing, externally for sure. Maybe aluminum sheeting for the roof.
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #75 on: October 10, 2019, 09:21:48 AM »
I have mixed feelings about the raptor liner. Not sure how good it would stay stuck on primered, sealed, finely sanded wood. It would suck to have that stuff start peeling off in sheets (like it is on my aluminum ranger bed).
...plus you need to spray clear, or paint on it to keep it from fading (like my bumper, and I think yours also).
I'd fiberglass the whole thing, externally for sure. Maybe aluminum sheeting for the roof.
Ken, did you look at the one I used for a basic design to modify? Wes first covered the plywood with fiberglass resin, and a thin sheet of frabric, then primed over that then painted it with Tractor Supply Company tractor paint. He then covered the lower segment with the raptor and after seasons and many overland trips it seems to be holding up.

True to what you said, he did start with the poylester resin to seal the wood.

I have another product that you will see in the coming installments that is a two part epoxy made by sherwin-williams that is kick-butt. It is very expensive, but talk about a one and done coating that is as thick as catfish snot, I may go to that. We have several installments to get through before we are there, but when we do get there, I'd like an opinion at that point.

And fellas, the Sawzall is locked up on this one!

And Tex, If you look at the renderings I drew up early on, the thing did have a tilt up roof, which it just may get. Disadvantages is that it limits headroom a little bit. Bennies are less space to heat and cool, simpler design, and stronger than having the whole roof hangin' out in the proverbial, breeze. So ya, the floor's open on that discussion to be sure.
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Offline JR

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Re: OverLanding Camper Build
« Reply #76 on: October 10, 2019, 10:55:13 AM »
I would think about a liner above the wheels maybe running back a bit. Built great is good but getting hit with road junk all day on and off road will chisel anything away.

Since it is flat, how about a sheet of ABS contoured to wells and bottom, something like this; /-\___      Just an idea,,,,,,,,,,,,,,
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Offline Bigdave_185

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Re: OverLanding Camper Build
« Reply #77 on: October 10, 2019, 11:05:43 AM »
What Sherwin Williams product did ya go with?


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Re: OverLanding Camper Build
« Reply #78 on: October 10, 2019, 01:52:19 PM »
https://en.m.wikipedia.org/wiki/Hughes_H-4_Hercules


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Hour away from me and i've never been to see it... driven right past though on the way to the beach many a time.
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #79 on: October 10, 2019, 02:09:28 PM »
What Sherwin Williams product did ya go with?


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A two part epoxy IAW our conversation...
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #80 on: October 10, 2019, 02:12:06 PM »
https://en.m.wikipedia.org/wiki/Hughes_H-4_Hercules


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Hour away from me and i've never been to see it... driven right past though on the way to the beach many a time.
It's in Oregon at the Evergreen aviation museum at the moment.
I was given a tour of the plane, well the cockpit and inside the wings. I sat in Howard Hughes captain seat and put my hand on all those throttles, or whatever you call them...

At the time I sat in it, it was the worlds largest aircraft.
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #81 on: October 10, 2019, 02:19:30 PM »
Lets do some more assembly

Next up I added the "wings" or the extension panels to the sides

Just like before I used the joint planer to cut a slot that I glued an oak spline into that aligns and joins the two panels
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #82 on: October 10, 2019, 02:20:21 PM »
Then with an abundance of glue, slid the wing panel into place and clamped it to dry
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #83 on: October 10, 2019, 02:21:18 PM »
I had to create some clamping blocks to grab onto for the right side
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #84 on: October 10, 2019, 02:22:07 PM »
And with that in place, I was able to glue in the right side wing panel
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #85 on: October 10, 2019, 02:23:48 PM »
I mentioned an integral water tank earlier, well, here is the forward bulkhead going in
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #86 on: October 10, 2019, 02:27:14 PM »
That was screwed and glued from all sides and was given a gusset/bracing to the floor panel

After installing that the back slant panel was cut with 45's at either end, then fitted, glued/screwed and installed

This trough that was created is the integral water tank.

Most of these teardrop type overland campers have 20 gallon water tanks, and you may see 30 gallons. This tank will hold 57 gallons allowing for frequent showers if desired.
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #87 on: October 10, 2019, 02:28:42 PM »
Showing the inside of the tank...
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Offline Nate

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Re: OverLanding Camper Build
« Reply #88 on: October 10, 2019, 02:35:31 PM »
https://en.m.wikipedia.org/wiki/Hughes_H-4_Hercules


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Hour away from me and i've never been to see it... driven right past though on the way to the beach many a time.
It's in Oregon at the Evergreen aviation museum at the moment.
I was given a tour of the plane, well the cockpit and inside the wings. I sat in Howard Hughes captain seat and put my hand on all those throttles, or whatever you call them...

At the time I sat in it, it was the worlds largest aircraft.

Evergreen aviation is now closed/out of business.  The museum is still there and still has the name on it.  There is a member on of this forum that lives 1 mile from that museum.
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Offline JR

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Re: OverLanding Camper Build
« Reply #89 on: October 10, 2019, 02:55:55 PM »
To bad its closed. Funny they can't find a real home for it with all that history, just hard to move!

Sat by the Queen Mary for many years when I was down there.

Build looks great, like to see the setup for the axle and frame? (seal it good and put a trolling motor on the back)

« Last Edit: October 10, 2019, 02:58:19 PM by JR »
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Offline wyorunner

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Re: OverLanding Camper Build
« Reply #90 on: October 10, 2019, 04:47:37 PM »
Holy moly, 57 gallons rear of the Axle!! I mean I see most of the camper is front of the axle but dang, that’s 456lbs of water. Then you add your spare swing out bumper mix thing you’ll have back there...that’s a lot of weight back there but, I guess because there’s only two feet behind the axle in total
Maybe you need that much weight to balance it neatly!

I look forward to seeing this continue to come together!

Offline Flyin6

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Re: OverLanding Camper Build
« Reply #91 on: October 10, 2019, 05:56:20 PM »
Holy moly, 57 gallons rear of the Axle!! I mean I see most of the camper is front of the axle but dang, that’s 456lbs of water. Then you add your spare swing out bumper mix thing you’ll have back there...that’s a lot of weight back there but, I guess because there’s only two feet behind the axle in total
Maybe you need that much weight to balance it neatly!

I look forward to seeing this continue to come together!
Yea, looking at it as is with all that weight out back, you may think it is rear heavy, but there is a lot of stuff still going to be added. Like 24" compartment in front of the camper along with a steel frame and interior fit out and gas bottle, frig, generator, batteries and other things, all going to be added well forward of the wheels.
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Offline wyorunner

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Re: OverLanding Camper Build
« Reply #92 on: October 10, 2019, 06:36:10 PM »
Holy moly, 57 gallons rear of the Axle!! I mean I see most of the camper is front of the axle but dang, that’s 456lbs of water. Then you add your spare swing out bumper mix thing you’ll have back there...that’s a lot of weight back there but, I guess because there’s only two feet behind the axle in total
Maybe you need that much weight to balance it neatly!

I look forward to seeing this continue to come together!
Yea, looking at it as is with all that weight out back, you may think it is rear heavy, but there is a lot of stuff still going to be added. Like 24" compartment in front of the camper along with a steel frame and interior fit out and gas bottle, frig, generator, batteries and other things, all going to be added well forward of the wheels.

Yea this is what I was figuring. It’s amazing  how much things forward of the axle add up. Figured this out the hard way on our last 5500 mile trip pulling with a bed load in the taco. Very nice work by the way! Wood is not something I’m very good at.

Offline Flyin6

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Re: OverLanding Camper Build
« Reply #93 on: October 10, 2019, 07:41:03 PM »
Thanks T
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #94 on: October 11, 2019, 06:32:02 PM »
Next I constructed a lip all around the top of the tank to give me something to screw the lid to
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Re: OverLanding Camper Build
« Reply #95 on: October 11, 2019, 06:33:13 PM »
Using drywall mud, I rounded out the corners to help the fiberglass lay in better
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Re: OverLanding Camper Build
« Reply #96 on: October 11, 2019, 06:35:24 PM »
Showing the cubic inches of water I'll have if everything is full. This number does not account for space lost to the gussets and the rounding out of corners
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #97 on: October 11, 2019, 06:37:03 PM »
Then I cut a piece of plywood to use as the lid of the tank
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Re: OverLanding Camper Build
« Reply #98 on: October 11, 2019, 06:39:48 PM »
Then I started the fiberglass work. First the entire inside and the underside of the lid was given a coat of polyester resin and allowed to set up until it was very tacky

The first layer is a very heavy 24 oz layer that is thicker than tent or tarp canvas. I had pre-cut many pieces, so I could proceed quickly
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Offline Flyin6

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Re: OverLanding Camper Build
« Reply #99 on: October 11, 2019, 06:41:09 PM »
I was not bashful in the use of the resin. I used well over a gallon on this 50+ gallon tank interior in several applications
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