2017 F-550 Camper Build - Ground Up

[PacificNorthWestJeeper]

I was able to square away the wheel wells today. You can see (below) where the factory wheel well liner stops and the BuckStop wheel well liner starts. Essentially you reinstall the factory liner and then install the BuckStop liner which the factory liner just rests on top of. Eh, it works....
My mind went to making aluminum wheel well liners and bolting them in but.....'good enough for government work'.... I'm moving on....
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[PacificNorthWestJeeper]

Another day another step forward.
I mounted the 3H Air System under the cab on the driver side today.
I used rivnuts that I put into the bottom framing of the cab and altered the bracketry to make it work.
Now the whole box bolts in and unbolts easily for service. Next step is the wiring.
I chose this spot because I did not want to mount this system above the exhaust in the back, which was the only spot left back there.... I spoke to the guys at Kelderman who told me that they had used this spot on a few trucks in the past so I went for it.
It is tucked up high enough so that other items under the truck will hit something before the air until does. This also still kept the air drier easily serviceable.
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[Kingsize24]

Another day another step forward.
I mounted the 3H Air System under the cab on the driver side today.
I used rivnuts that I put into the bottom framing of the cab and altered the bracketry to make it work.
Now the whole box bolts in and unbolts easily for service. Next step is the wiring.
I chose this spot because I did not want to mount this system above the exhaust in the back, which was the only spot left back there.... I spoke to the guys at Kelderman who told me that they had used this spot on a few trucks in the past so I went for it.
It is tucked up high enough so that other items under the truck will hit something before the air until does. This also still kept the air drier easily serviceable.
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View attachment 858836View attachment 858837

Looks good to me. Can that system also supply a heavy duty cycle for tires, tools, and such? Or is it for the suspension only?

 

[PacificNorthWestJeeper]

Looks good to me. Can that system also supply a heavy duty cycle for tires, tools, and such? Or is it for the suspension only?

It is for both, it has 2 Viair 444C compressors, info from Viairs' website:
VIAIR’s 444C compressor dual system offers unmatched durability, power, and performance for air suspension and other demanding applications. Reaching 100% duty cycle at 100 PSI, the 444C is a robust, powerful solution for air suspension systems, horns, truck and SUV tires, and more.
I ordered a different air tank, ditching the one I bought. The new one is 8 gallons, it will be here in 2 weeks...

 

[Kingsize24]

It is for both, it has 2 Viair 444C compressors, info from Viairs' website:
VIAIR’s 444C compressor dual system offers unmatched durability, power, and performance for air suspension and other demanding applications. Reaching 100% duty cycle at 100 PSI, the 444C is a robust, powerful solution for air suspension systems, horns, truck and SUV tires, and more.
I ordered a different air tank, ditching the one I bought. The new one is 8 gallons, it will be here in 2 weeks...

That's an amazing setup man! Definitely jealous of the air supply.

 

[PacificNorthWestJeeper]

I was able to get the brakes bled this weekend and the front tires on...
Below are picks of it at ride height. You can see the big gaggle of wire underneath which is from the air system which I still need to run and wire up...
I can go up roughly another 5in or down roughly another 5in from here.
The BuckStop fenders perfectly cover the tires.
Next from here is:
- Install front bumper
- Install winch
- Install lights
- Complete wiring for: air system, 58g fuel tank, lights, winch.
- Run air lines to air system from air bags.
Getting closer to the camper build...
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[PacificNorthWestJeeper]

Weather is horrible and the truck won't fit in my garage, not a lot accomplished today.
My wheel locks from Advanced Wheel Locks came in today. After searching the net these seem to be the best out there. If they want the tires and wheels they'll get them but these locks should give them a headache for a while. I am dropping them off at the powder coater to have them coated black, A.W.L. does not offer them in black, bummer.
I also prepped the 8 gallon air tank with plugs for the holes I won't use and a bleeder valve & a 200 pound pressure relief valve.
As a side note the Airmaxx tank had 2 ports where the threads were jacked, I had to buy 2 taps to tap out the threads to be able to get my NPT fittings threaded in. You get what you pay for with air tanks, may be worth spending more if you need a tank.
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[Drell42]

I just picked up a 2020 F550 and am looking at doing a very simular build. Its great to see all the work you have done so far. Thanks for the detailed build. I will likely be in touch for help soon.

 

[Skinhyfish]

What kinda camper build you going to do?

 

[PacificNorthWestJeeper]

Drell42: "I just picked up a 2020 F550 and am looking at doing a very simular build. Its great to see all the work you have done so far. Thanks for the detailed build. I will likely be in touch for help soon."
Thank you, PM me amy time, this is not an easy venture at all, Ill help with what I can.

Skinhyfish: "What kinda camper build you going to do?"
Well I have several thoughts and have not landed on one. My though today is Defiantly going to use a sprung subframe and then put the camper on it. I was going to use the 4 point subframe but the more I read about the Con's the more I have steered away from it.

- Build my own framed out with aluminum, side with fiberglass inside and out and use, and Azdel for rigidity. Then spray foam for insulation.
- GlobeTrekker's complete kit...
- OffGridCustoms assembled camper with one door. Then install my own windows, skylight, etc from there.
- Cascadia Composites, like OffGridCustoms go with just the shell and build out myself from there.
'
It's funny as I read back through this build how I have changed my mind on things. Like I was going to use KING Shocks and here I sit with FOX shocks installed. That happened primarily because Kings customer service was horrible on the phone, like I was bothering them and they were not interested in talking to me, and when I called FOX they were very helpful, personable and got me what I needed.. It will be interesting to see how it all pans out, I'm not even 100% on how it will, LOL!
Thank you both..

 

[PacificNorthWestJeeper]

A smidge more headway this past weekend. I made an air tank mount out of ¼ plate, bent and welded it up to support the air tank on the inside of my frame.
It worked out fine and the air tank is now mounted. I was able to spray ceramic heat shield on the exhaust below the tank. I also wrapped the exhaust with heat wrap as well.
Next step is to bend up some aluminum and make a heat shield separating the tank and the exhaust. With 3 layers of protection heat should not be an issue on the tank.
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[Krangmang]

Following, I'm looking to fit similar things in the same places on a 2003 F550, no air system though but that means more room for fuel!

 

[PacificNorthWestJeeper]

I picked up an aluminum sheet and used my brake to bend it up to make a heat shield.
I used 3 stainless steel stand-off mounts with 3.5" clamps.
I also sprayed the shield with the Thermotech ceramic heat shield spray.
All I am trying to do is keep the heat away from the air tank and lines.
I am thinking worst case scenario, in the desert 120 degrees outside going up hill with a heavy load. That will create a lot of heat..
Still need to rebuild and paint front & rear drive shafts, probably leave that for one of the last things.
Im also saving room in between the frame rails for a 30 gallon gray tank that the sinks and shower can feed into. Im pretty set on a cassette toilet so I won't need a black tank. The 100 gallon water tank will be inside with the intent of it being custom made into stairs to get up into the bed over the cab - still a ways off from this...
I already made up temporary rear brake light housings (see on floor in pic) and need to weld those up. I bought a template for my plasma cutter just for those light cut outs, worked perfectly. Link: template oval plasma cutter lights
Next up Bumper/16.5ti/lights mounting.. Then wiring for lights, winch, H3 air system and 60g fuel tank as well as plumbing the airlines to the H3 system.
Wish I had more time than just weekends..
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[Andrew_S]

Absolutely awesome build, talk about doing it once and the right way the first time.
Any plans to add a skid for the fuel tank?

 

[PacificNorthWestJeeper]

Andrew - Thank you, takes a lot of time...
So I was planning on making a skid plate until I talked to the guys at Titan.
They said there is no need, they have only had 2 ever reported broken. One was purported to have a steel rod thrown up from the tire on a highway spearing the tank. The second one was questionable as to how it sustained a hole. These tanks will hold the weight of the truck with no problem, they are pretty stout. Beyond that they have a lifetime warranty too, all that to say I am not going to use a skid plate.