New Expedition Camper Build (CRT14)

[ahb1989]

After posting for advice about the exterior coatings on a new camper model i'm building I was informed that a build thread wouldn't be out of order (Thanks PC06) I have read the rules of the forum but Moderators please let me know if I need to adjust any thing here.

The coatings thread.
http://www.expeditionportal.com/forum/threads/152930-Exterior-finish-opinions-for-new-expedition-trailer


This will be updated as I get time to bring it current and then as I complete the camper and I welcome any feedback, this is very much a work in progress. Eventually I will be bringing this model to market but it should be noted that this camper is a work in progress and I already have noticed several things that I plan to do different. That said a lot of ideas spawned from other ideas found on this website so I hope that others will get ideas from my work and that the cycle will continue. I worked in the RV industry as a Technician for several years and was always fascinated by the smaller teardrop trailers but most of the available ones were crudely constructed and not made for off highway adventures. I had a friend approach a few years ago and commission me to build a camper he had "napkin" drawn and the thought process started.



This was the start of the frame. Additional cross members were added as well as the cross member for the axle system.

 

[ahb1989]

After some rough drafting of my own we started laying out some walls. Ultimately we built one wall that we were satisfied with and then build a full sized jig for it so that it could be duplicated with ease.

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[ahb1989]

After ordering some new wheels I came home with these mounted (31x10.5x15).

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[ahb1989]

The walls semi completes and welded to the chassis.

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[ahb1989]

We decided on a hybrid floor. We stitch welded 16 gauge steel sheet metal to the chassis, waterproofed the edges and then used 3/4 flooring to serve as a thermal break between the mattress and the outside.

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[ahb1989]

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[ahb1989]

One side wall on, after chassis paint. Note the rear receiver hitch that is directly welded to the main draw bar that houses the main hitch as well.

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[ahb1989]

Front tongue reinforcements with 2x2x.120 covered in 16 guage steel then capped with 1/8 angle iron.

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[ahb1989]

Side pic of camper. The trailer has 10" brakes and soft 8 steel wheels.

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[ahb1989]

Left side wall cut for rivets, door, hot water heater, kitchen drain, electrical hatch, water inlet and city water fill, and the outside shower.

 

[ahb1989]

Rear door threshold manufactured and installed.

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.120 Aluminum trim on the sides.

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[ahb1989]

Sneak peek at half of the solar system. This model will have a total of 200 watts of solar panels on-board.

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[ahb1989]

Rear 3/4 shot with rear door installed.

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[ahb1989]

Decent view of the suspension

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[ahb1989]

Front shot. Disregard the trim laying on the front and I just noticed how dirty it is, its covered in aluminum

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