Open Roads Forum

Print  |  Close
Page of 52  
Prev  |  Next

Topic: Our custom true flatbed truck camper build thread

Posted By: BoonHauler on 09/07/14 07:37pm

When do we get to see the battery box and solar panel set up?......as if you haven't been busy with the build so far....LOL!


05 RAM 3500 CTD 4x4 Q/C Laramie DRW/NV5600/3.73, B&W Gooseneck, MaxBrake, PacBrake PRXB, Brite Box Fogster, BD steering Box Brace
2014 BoonHauler 3614


Posted By: pjay9 on 09/09/14 08:34am

Jfet wrote:

I think they bent that safety bar when backing up to a loading dock, but who knows?

We did put boxes on the other side but there is a missing tooth where we needed a slightly different type of box for the propane storage (and generator storage). I will custom make that box. We plan to have it hold the EU2000i plus 4 standard propane cylinders (for easy exchange when there are no fillup locations).


Wiil you build the box so the gen can be run in the box?


2005 Lance 1161, 2004 Dodge CTD 3500 Dually 19.5's Stabiloads Roadmaster Sway, 2009 20' Raider 185 Pro Fish 90hp & 9.9 Yamaha vintage Penn elec.downriggers EZLoad roller trailer



Posted By: Jfet on 09/12/14 07:23am

BoonHauler wrote:

When do we get to see the battery box and solar panel set up?......as if you haven't been busy with the build so far....LOL!


I still have to build the solar panel mounting frame. I have been concentrating on the inside electrical, which includes fitting the Magnum MSH4024M inverter/charger, Midnite Classic 150 MPPT solar charge controller, and all of the required breakers, switches and fuses in a space no bigger than a 19 inch TV. It is tight but looks good. For our use the Magnum doesn't even get warm or have the fan come on (during 40 amp absorption charging the transformer temp never got above 110F and during a 30 min run of the air conditioner the FETs never got above 90F). I will of course post pics when I am done.

pjay9 wrote:


Wiil you build the box so the gen can be run in the box?


Yes, that is the plan. We may make a slide out device that holds the gen in the box so to have easy access for cranking/oil change. I just need to source some slides that can handle grit and grime.


Posted By: Jfet on 11/01/14 08:55am

Started construction Friday on the garage pod!

I had forgotten how quick you can get a structure formed with steel after the pain of working with wood. Tack, tack, 20 seconds later you need a sledgehammer to break it apart.

Here in about a day we went from a pile of steel to a fully tack welded base frame for the garage pod, completely level and diagonals matching to within 1/64".

We decided to make the garage pod 10 feet long instead of 11 feet. This way it will only overhang the flatbed by 1 foot which should be visually and structurally reasonable (and save weight). It is going to have a full ramp rear door and a passenger side teardrop trailer type mini door (for occasional access when you don't want to lower the ramp). We are also making the garage pod 1 foot shorter in height than the camper pod and will have a roof rack for kayaks and such on the garage pod.

[image]

[image]


Posted By: emaav on 11/01/14 11:33pm

I really enjoy the work you are doing to make it your own.


Me (Eli)
Better Half (Trinity)
2 cats
1999 Chevy 3500
1993 Shadow Cruiser 21F21RD



Posted By: pjay9 on 11/02/14 12:06am

keep us posted on your other doings in the TC too...this is interesting. THX for your efforts to post.


Posted By: Jfet on 11/17/14 01:07pm

A weekend of tack welding and we managed to get the full frame of the garage pod together (sans ramp door).

It is hard to glean a lot of information from the pictures because of the cramped build space, but there are some interesting features.

1) We of course went with the same socketed quick connect system as we did in the living pod so the same jacks can be used to load/offload either pod.

2) We decided to weld in shelves on each side of the garage that hang down 2 feet and extend for almost 18 inches. This will provide a ton of storage space for gear and tools. It also adds strength to the walls and roof system to have the shelves part of the welded frame.

3) In a similar manner, we welded in a workbench across the entire back wall (8 feet long, 2 feet deep). This will provide a good surface for various future projects and maybe a small cnc mill/lathe.

4) In order to have some access to the pod without opening the ramp door, we added a small door meant for teardrop trailers (36" high) on the passenger side. It does have the advantage of fitting under the shelf system.

It should make a very useful storage garage for our motorcycles and gear and also provide a good area for metal/woodworking while on the road.

Next job is fully welding all of the joints, then the process of installing the aluminum skin and roof.


[image]

[image]


Posted By: pjay9 on 11/17/14 11:56pm

You need a tommy -lift! Is it aluminum? Looks good!


Posted By: Jfet on 12/27/14 09:00am

Managed to get the 0.063" aluminum skin on the garage pod, also the plywood roof and the 0.040" aluminum continuous roof coil in place.

Still need to make the ramp door and cut out the opening in the aluminum for the teardrop trailer type door (you can see the place for it in the 2nd picture).

Work on the main camper has stopped for now until we get the garage pod somewhat finished and painted, but we did get the floor tile, some cabinetry, and sofa installed. I will get some pictures of that up soon.

[image]

[image]


Posted By: kereams on 12/27/14 09:25am

Your work continues to impress me and make me jealous! Great job. Love seeing the updates.


*2011 F350 SRW CC/LB/PSD - Mods: Custom overload springs with custom early engagement blocks~Firestone Airbags~Hellwig Big Wig Rear Sway~Rancho RS9000XL~Bilstein Steering Damper~19.5" Hankook DH01'a on steel wheels.
*2012 Chalet Ascent S95R Camper


Print  |  Close
Page of 52  
Prev  |  Next