Project Build - V3 XV

[ski_bike_camp]

The start of any good build should begin with a post to this forum...

While I have done a lot of searching, researching and learning on this forum and others, I am sure my ideas & plans can use some input or adjusting. I am hoping over the next 12-24 months there will be lots of posts. I will attempt to keep the pictures of progress etc updated regularly. I am hoping you all will keep feeding me your thoughts and helping me along the way.

By way of background this is my second big build. My first was based on a 2011 Merc Sprinter 3500 170" Ext. I am taking what I learned with the Sprinter, adding in my boat building skills/background to come up with an ultimate, ski gypsy/kite gypsy, mtn bike camping truck that I hope to see a lot more of our world with.

My key parameters:
(1) - Do not get stuck getting to & from skiing, the desert or an ocean. Which to me means a proper full-size 4x4 with the right suspension, wheels, & tires.
(2) - Be able to keep it warm. 70 degrees inside, even when it is 15 outside.
(3) - Dedicated bed. I don't want to be folding something out, re-arranging cushions etc.
(4) - Inside head/shower. I have learned when gypsying around in swanky ski area parking lots, slipping out in the middle of the night is not always ideal and having to leave your fantastic spot in the desert daily is a drag too.

How do I plan to solve for the above?

I am going to build a hard-sided truck camper on a full size Dodge Ram 3500 4x4 chassis. Some of my inspiration comes from vehicles like: The Turtle V (I have to thank Gary for all of his gracious input already), Bullet XV & The Earthroamer. However, I plan to work really hard building it light using similar construction methods used today in modern ocean racers.

The Box or Cabin:

I am building this using foam sandwich contruction, using Divinycell H80 core and 600gm carbon fiber skins. The epoxy is Pro-Set laminating epoxy, vacuum bagged with a resin infusion technique to ensure the lightest, stiffest, stongest panel within reason (it is a truck mounted box afterall, versus a high-tech sailing skiff). I expect the box to weight approx 700lbs empty.

The Chassis:

Dodge Ram 3500 Mega-Cab DRW - GVMW = 14,000 lbs. The truck frame will be lengthened and stiffened @ Precision BodyLine in Utah to accomodate a 10' box. The wheel base will be approx 186". Suspension upgraded to Kelderman Air on all four corners and leveled (or lifted slightly) to accomodate a larger wheel/tire combination and gain additional clearance. The fronts/duals are being swapped out for Rickson Mfg 19.5" steel rims and Toyo M-608Z rubber. The truck will also get a new front bumper w/winch, increased fuel capacity from Titan, Air Dog Deisel Lift Pump/Filters. Dual 220 amp alternators (one to charge the truck, the other to charge the cabin batteries).

Mounting the cabin to the frame will be done using a 3-point approach similar to TurtleV, XV-Bullet or Fuso. The engineering for this and then the proper manufacturing of the mounts and pivots is still a WIP.

Cabin Interior:

The interior layout/furniture is going to be quite minimal and will be foam sandwich contruction with either epoxy paint or simple vinyl/pleather finishes. The goal is light weight, visually appealing and reduce the chance of mould. I also believe I have gone over-board with ventilation fans, windows, and a roof hatch to move moisture out of the box.

Other:

- I was able to get Seitz S4 windows. A small miracle given what I have read on this forum. But, I have them now and am not looking back.
- I ordered my entry door from Camec in Australia and they shipped it via FedEx and it arrived beautifully packaged.
- Heat/Hot Water is via an Espar deisel hydronic furnace from Rixen Enterprises out of Portland, OR. I have the identical system in the Sprinter and it is awesome.
- I will have approx 100gal of freshwater inside the heated space with no outside plumbing to reduce the risk of freezing
- Cassette toilet/head from Thetford
- 330w solar panel, Morningstar MPPT Sunsaver - I have this setup on the Sprinter as well and it works flawlessly.
- 800Ah Lithium Iron (iron versus ion) 12v battery capacity coupled with Magnum Energy 3000 Hybrid Inverter/Charger

My closing comment for this evenings post: I am doing this myself for two reasons. #1 - I think I can build a better mousetrap. Most everything else is too heavy IMO and that just creates wear & matinenance issues later. #2 - I can't afford to buy one or pay someone else to do it. I truly believe, that I can finish this project and be under $150K. The new truck chassis/mods is the biggest single cost at approx $80K unfortunately.

Thanks for having a look at what I am up to here in Breckenridge, CO.

John

 

[gmacmt]

Awesome!

I think that 150k is more than reasonable. Like, way more than reasonable. I'd be surprised if you couldn't build something pretty nice in the neighborhood of 35k for the box, and maybe 15k to modify the chassis.

Looking forward to following this build, check out jeep's thread in this section if you haven't already. link

As a matter of fact, his build out may check a lot of the boxes on your list, and come in somewhere around your desired pricepoint.

Whats the reasoning behind 100gal of water? Not saying it's a bad call, but that is a ton of water. Well, 2/5th's of a ton of water anyway.

 

[Darwin]

The only thing I question is why the mega-cab? The 4th gen Ram quad cabs seem to have enough space back there and it would eliminate the frame lengthening work? I prefer a regular cab, but I don't have a family.

 

[Littlehouse]

Have you seen this thread? Maybe a chassis cab would be a better fit? http://forum.aev-conversions.com/showthread.php?t=11062

 

[ski_bike_camp]

I did have a good look at Jeep's build thread. Pretty awesome. I wish I had his aluminum fab skills. Wow!

I am including the cost of my truck in my budget. Approx $55K plus all the mods (which could be another $25K).

The box/cabin is likely to end up being around $30K ish. The carbon, foam and glue is already $20K

But I support your optimism.

100 gals is what will nicely fit under a full-width bench I have. I might be a little less depending on how tight I fit some other systems in there. Basically once everything is in place, I am going to fit two custom poly water tanks in between. I don't think I would travel great distances full, but will likely top up before heading into the desert for a longer stay. Being able to shower off the Moab red dirt is pretty nice after a long ride.

 

[ski_bike_camp]

The only thing I question is why the mega-cab? The 4th gen Ram quad cabs seem to have enough space back there and it would eliminate the frame lengthening work? I prefer a regular cab, but I don't have a family.

Two kids, and animals. Plus, my bed will be over the cab, and I plan to sleep lengthwise. Therefore, I think it might look better.

The reason for the lengthwise queen is a plan to have a bunch of lite storage up in the sleeping area (clothes etc) on the sides. One of my biggest frustrations with my previous build was the lack of enough good storage. Stuff just seems to be everywhere.

A regular truck bed 8' may have worked, but I might still need to lengthen something to make the rear bumber etc work. That said, it might be worth another trip to the dealership with my trusty tape measure. My sequence is to build the box/cabin first and get it mostly ready to mount on the frame. Then buy the newest frame available. Versus spending 1-2 years getting the box complete and having a truck sitting next to it aging gracefully

 

[ski_bike_camp]

Test panels for V3-XV

FIG]348109[/ATTACH]

The test panels are done. Plus a smaller piece to show the perfs. Basically with resin infusion the glue comes through the perfs, both sides are done at the same time and a little "rivet" is created between the two skins.

1" thick H80 -= 14oz sqft
3/4" H80 = 13oz sqft

Very stiff and strong. Likely break your hand/fist trying to punch through this. But back it into a tree or light post hard, and I likely have a hole.

 

[ski_bike_camp]

Medallions arrived

Having the finishing touches already, help me get to the end

 

[jerstw]

Sounds like a very cool build. Look forward to seeing the progress.

 

[tommyt]

Looking forward to your build... Would you please go into detail why you chose H80 over high density EPS like Corning Formular 400/600 or Dow High Load 40/60? Do you know the H80 R-valure per inch? Thanks and best regards, Tom

 

[ski_bike_camp]

Looking forward to your build... Would you please go into detail why you chose H80 over high density EPS like Corning Formular 400/600 or Dow High Load 40/60? Do you know the H80 R-valure per inch? Thanks and best regards, Tom

I have to figure out this forum thing a little better. Looks like I have two threads going. I wonder if there is an easy way to combine them and only have the single updates going. Check out the latest photos here: http://www.expeditionportal.com/for...rt-V3-Explorer-Feedback-from-the-group-needed

But back to your question:

I went with the H80 becasue while it is a little heavier (approx .5lb per cubic foot) than some of the EPS foams, it is structurally much stronger.

I am relying on input and design from my International14 racing skiff buiding world. I did look at the idea of EPS (especially since I was using epoxy) but was warned off of it. None of my guys thought putting anything but the H80 or Corecell into the core structure was a good idea.

I am sure the R value is pretty low for what I am using (1"). I am counting on having a mostly air tight box as the reason I will be able to keep it warm.

I will of course need to vent out moisture to avoid condensation. But with very low air infiltration from the outside and the hydronic Espar/Rixen unit heating system (17,000 btu) which doesn't introduce new moisture like a propane furnace does, I should be toasty warm in the Colorado winters.

 

[ski_bike_camp]

The actual build thread. Although, I am mostly done now and have appro 6,600mi on it.

My next new build is about to start - V3 Explorer - Feedback from the group needed

Thanks to everyone for taking the time to review my post and provide your insight and comments ... My next build journey is about to startin earnest. It is likely to run a couple of years, but I have time. Having built up a 2011 Sprinter into an adventure type, off-the-grid camper van, I am...

expeditionportal.com