2003 F150 v6 North/ American overland project. Camper shell build

moscar45

New member
Hi guys, I've been a lurker here for a while, and I'm doing my first overland build. I've seen many encouraging ideas on here, and I'm getting my build and restoration underway.

About me:
I'm a recovering Jeepaholic, having had a 2006 rubicon rock crawler that I went totally overboard with. This build will likely be 20% the cost of the last.

I've been in the auto industry as a car dealer/wholesaler either full or part time for the past 7 years. I decided to return to school full time to finish my undergrad degree in finance after a 5 year hiatus, and pursue an MBA, so the high dollar toys had to go.

I plan on keeping my build inexpensive, sourcing my parts on the cheap and doing my own fab work. I am fortunate enough to have a full shop at my disposal.

Why I chose this particular truck:

Price. Its a 2003 with 48k miles on the clock, and it will be fixed and freshly painted for under 3k. I look at it as trading the entire truck for the price of a set of new Walker Evans and MTR's I had in the garage.

F 150's are sold in Mexico as well, so I'm not worried about serviceability or parts problems should I break down.

Coming from a jeep background, I don't need high horsepower. I have much familiarity with the 4.2 v6, and after the revision of the intake gasket in 2001 these engines are extremely long lived. There is also more room under the hood.

I like single cab long bed trucks. It is just myself, and my cattle dog, so I have sufficient room up front.

Why build: I plan on seeing the country, as well as Central, and maybe South America. I started my first business at 19, and have been self employed in 5 different ventures over the past 12 years-some good, some horribly bad. I realize that the change from entrepreneur to employee will alter my traditionally flexible schedule, so I decided that a trip next year will help me get some travel bugs out of my system before working for the "man" and waiting a year for my measly week's vacation. There's as much sarcasm as pessimism in that sentence.

Build plans:
I plan on building the truck modestly, not something that will stick out too much. I also plan on staring a small business in the spring that will require a pickup, so it will double as a work vehicle part time. I do need a swing out rear bumper, as I have a powered paraglider I will be bringing with me.

I bought a ARE MX series cap for $200, and it will be the basis of my camper shell. I originally thought I would cut out the top and make some form of westfalia style pop up, but I'm on the fence right now. I do have 15 yards of kevlar-glass if I get ambitious.

I want to do the following:
Build a simple custom clearance front bumper that uses the factory upper portion of the bumper, and just make a steel lower. with a receiver for possible winch mounting. I do not want to add unnecessary weight to the vehicle.

I plan on putting on full length sliders, a rear glider/ Jerry can carrier that will be flush with the bedsides and bobbed like the taco fellas are doing.

I'd also like to incorporate a couple 70's style bedside camper special doors into the build to maximize space and give me a spot for a camp shower, etc.

I plan on making the interior of the shell minimalist. I've restored fiberglass scamp campers before, so I'm ok with some fiberglass work, and rat fur insulation etc. I was considering tabbing in upper fiberglass cabinets, but I'm going to have to consider stresses offroad on the shell.

I'm going modest at 265/75/ r16--biggest I can go keeping stock gearing. I'll go with a simple soft locker to keep it cheap but functional off road. Maybe one in the front 8.8.

I'm going to make 2 sets of tracks and mount the bed longitudinal, as well as the simple galley/storage on the right. They will slide out the rear, with fold down legs, and will be fully removable.

I'll have a full tool box against the cab, with spares. I prefer to do my own work, and will keep a spare starter and alt.

I want to put in a simple roof solar setup to power the laptop.

There's likely much more, but this is my start.

Pics of the truck:

7777968_6_I.jpg

7777968_2_I.jpg

Right now the roof is cut off, and the new front clip is on. Bedside repaired.
I picked up a mismixed gallon of nason basecoat for $50. so she will be a midnight blue, with raptor liner lower in either silver or tan. The MX camper shell is Arizona beige, so maybe that will be it.


I'll keep updating, there's much more I'm prob forgetting.
 
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Jim Rogers

New member
I'll keep updating, there's much more I'm prob forgetting.

I'll definitely be following this. I have a 2002 F150, regular cab, 4.2 V6 that I will be doing in much the same way. Mine is also blue! (But it's a short-bed.)

I got a used no-name topper that is higher at the back than the front, and next spring/summer I plan on making a minimalist camper out of it.

So I'll be watching how yours goes.

Keep posting!
 

Atticus_1354

Adventurer
I am looking forward to your build. Do you have any photos of bumpers that are like what you want to build? I recently switched to a 2003 f150 and have been thinking about making my own bumper as well.
 

Rovertrader

Supporting Sponsor
I have two NIB TJM alum front winch bumpers for this model truck- pm me for a super deal, need them gone. And congrats on the build, and best of luck on the crawler recovery as mine is not going so well...
Cheers
 

moscar45

New member
Thanks for the replies guys. Rover-sent you a pm.

Jim; My topper is an ARE MX, it has a rise as well. I wanted to be able to build a bed on the driver side and be able to sit up, even if I don't make some sort of a pop top. I do want to make the platform hinged/racheted in the middle like long summer lounge chair so I can sit up. Unlike some I've seen, I want a center isle, not a big covered area.

pic of the topper:
Trucktopper.jpg


Atticus;

For the front bumper, I'm planning on trimming the outermost corners to make them more angular like the off road bumpers. I also wanted to use the stock uppers, and just make a steel lowest portion to keep the weight down. I plan on making it flush with the bottom of the frame rails so I have the most clearance possible. If that doesn't work, I'l go a prerunner style and throw some filler panels in because I'm not into tube bumper looks. I'll try my hand at paint to mock something up.

Here's a pic of the front bumper style I might go with if the steel lower mated to the factory upper doesn't work:
FrontBumper004.jpg

This is certainly not my first choice.

For the rear bumper, I'll be trimming the bed side and making a full wrap, and adding a swingout with basket to carry my paragliding equipment. It will add some weight, but I don't need extreme beef, just clearance and utility.
Some pics I'm using as inspiration.
DSC00831.jpg

DSC01838.jpg


For the sliders, I'm making them full length from under the fender to the end of the bed. This will allow me to make a functional storage box like the old camper specials in the forward bedside for a camp shower, etc. I want to maximize space, and having the sliders there will protect the underside of said box while offroading.
I'm going to style my sliders off of JCR. Simple and effective.
JCRsliders.jpg


pic of the bedside storage I'm going for:
bedsidestorage.jpg


I'm also thinking about changing the front end on the truck. I'll be keeping it a while, and with the low mileage I think I'd be justified in updating the look. This chassis shares the same with the expedition, as many already know. The f150's chassis has changed over the styling changes of the past decade, but the expeditions has not. I can very easily bolt on the new front end of the 07-up expedition and in my opinion give the truck a serious update stylistically. On the fence about that since it doesn't add any functionality.
Pic of an 03 f150 with an 07 expedition front clip. No welding, just bolts right on.
truck1-1.jpg
 
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Atticus_1354

Adventurer
I like your ideas for bumpers. I also like those sliders and want something like that for my truck.

I am thinking about trying to make something like this for my truck since I don't want a winch on this truck.

CtxDn.jpg
 
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Rovertrader

Supporting Sponsor
Here are a couple pics, and they have the end returns that bolt on, and all mounting hardware- and they weigh next to nothing...

Ford 150 TJM front.JPGFord 150 TJM rear.JPG
 

goulou67

New member
i have a 2002 f-150 ford long-box 4.2 v-6 with 180.000 km on it, still running strong ,good on fuel in the backcountry and for my camper haulin .see my pics in the hardshell camper section 3 rd camper!
.next step is a warn winch and 31 inch bf,s on her for the spring!!!!!!
 
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