1977 Pop Up Camper Rebuild

[TheThom]

I've got the folding shelf/counter built. That ended up being more work than I thought it would for such a simple shelf. Between the facing covered in fabric, tweaking the dimensions, and figuring out the best way to attach the hinges, it took a bit of brainstorming/fiddling. I'm going to stain all of my counter top wood and table at the same time, so there's currently no top on it.

Here it is collapsed

Here it is set up

For the doors, I'm hoping to "borrow" and idea from the conqueror trailers-but I'll see if the upholsterer can use some tan canvas to match the main canvas

 

[TheThom]

After a trip out of town and a family visit from a nasty gut bug, I finally have a little time to work on the camper.
I'm still working on the interior. I built the cabinet inset by the door

I made this tray-like box

I laid out the items that are going in the insert: first aid kit, fire extinguisher and bear spray.

Then I installed it as part of the cabinet

Then I put more of the fabric covered panels in place. It's really starting to come together

The wood surfaces that you see are going to be stained to match the floor. I'm almost done with the interior panels. Then I have the interior wiring, building the table top, and staining the counters/tables.

 

[VanIsle_Greg]

Kool!

 

[AeroNautiCal]

That's looking really lovely!

 

[Expedition.Report]

Cant wait to see this completed!!

 

[Backroad Explorer]

Thom the trailer is coming along Handsomely.

I realy like The Emergency Center by the door.
Just a thought, do you have any leftover flooring? Maybe do the seat/step/storage in it to match the floor.

 

[Funrover]

I am liking where this has continued to go!

 

[Mark Harley]

Great progress! Keep pushing forward camping season is coming fast.

 

[TheThom]

I built the table. It's made from 1x6 nice pine stock. It's biscuit jointed together and then cut to size. Here's how I bolstered the underside. I still need to round the edges, do a lot of sanding and stain/polyurethane.

Here it is set up in the camper

And here it is collapsed down for sleeping. I was worried it wouldn't be strong enough, but it's VERY sturdy when sitting, lying, bouncing on it.

The upholsterer has my cushions and I should get those as well as the canvas cabinet doors back in the next week or so. It's finally starting to come together. Getting excited about finally getting out and using it.

 

[TheThom]

I got the cushions back from the upholsterer. I bought a 2.5" memory foam mattress topper and she cut it to size and made covers. They're a bit thin, but for bench seats, they'll be OK. She made the covers a tad big to allow for shrinking in the wash. Best of all, I had the canvas already for a chair recovering project that never panned out. The two small cushions propped up against the wall will cover the table when collapsed

I also got the canvas cabinet doors back and the memory foam for the mattress cut. I sanded the table and countertops. Now I need to stain and apply the polyurethane. Still need to wire the circuit panel too.

It's coming together.....

 

[Mark Harley]

Looks nice!

 

[TheThom]

I'm on a mad dash to get as much done as I can before I"m stuck on crutches (later this week [O])

Got a couple of pieces of counter stained and finished. The bench step/storage is using floor polyurethane like the floor did. The counters used spar outdoor polyurethane.

The top that's still open will be hinged. The other portion needs stain/poly on both sides so it'll take a bit longer.

I got the cabinet doors from the upholsterer installed. They aren't 100% what I pictured, but they'll work fine.

The back portion of this counter top has 1/4" Neoprene trim (had some left over). It'll rest on that when folded over to protect the floor/hinge

Now, some more poly on the table, counter and step; some wiring; and then putting the bed roof and canvas back on!

 

[TheThom]

I'm continuing my big push before I have to take a few weeks off for ankle surgery rehab.

I got all of the interior cabinets done!

This cabinet is hinged to allow access to the electric as well as the outer valves that will be used to run the propane hose for my Little Buddy heater

Here it is with the hinge up. Ignore the wring. I inherited the battery with the camper. I've been curious if it will hold up but today it was at 4.7V and the Battery Tender pronounced it dead with it's flashing red light after several hours. So, it looks like I'll be buying a new battery sooner rather than later

This long low cabinet is dual purposed: 1) it will serve as a step up into the bunk and 2) it's specifically designed to fit my Camp Chef Explorer stand up stove

I used the same stain as the floor, but this didn't have CPES on it. I suppose that the reason for the difference. That and the flash magnifies every. single. mistake.

Anyway. Tons of wiring left. Need to put bunk ends on. The roof will get re-built next season and I'll use it as is this season. More than likely, (unless I post final table pics) this is the last significant update for quite some time

 

[Expedition Essentials]

Coming along great! Looks good!

 

[TheThom]

I was feeling motivated so I attached the bunk ends. Here's some pics of the first one. I was nervous, but the poles fit in perfectly. I was pretty happy since I disassembled these bunkends November 2011. I was pretty pleased they fit so well.

Here's a pic of both of them

To give you some perspective of this sucker's hieght - I'm 6 feet even and the mattress top is even with the top of my shoulder.