1981 K30 Flatbed Camper Build

[Rusgo]

A decade ago I did some major work to this truck. Came factory with a big block, Dana 60 front, corporate full floater rear.

Frame off rebuild.
Port electronic fuel Injection on big block.
NV4500.
High crossover hydro assist steering
A thousand other things

...And its been sitting forever

So lost the bed on craiglist a few months ago and finally got started on the flatbed frame for a custom cabover.

Been secretly building up materials as they pop up for the cheap on classifieds. Lots 1/16" aluminum sheet. 30mm fiberglass reinforced Nida. 3/16 angle aluminum. Things are starting to happen.

More coming soon.

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[Rusgo]

Steel flatbed using 2x4 1/8th tube. Flatest squarest straightest thing I've ever made.

I dont trust the flatness of my 1950s garage floor, so maximized the use of clamps, levels, squares. Spent as much time checking numbers as actually fabbing it.

7' wide 8' long

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[chilliwak]

That is a really nice looking flatdeck you have in the making Mr Rusgo. It will be interesting to see what you put on top of it. Cheers, Chilli...?

 

[chris_the_wrench]

Very cool start. Sounds like your scoring some goodl materials off craigslist. Much better luck(skill) than I ever have!

Looks like you had some 2" square underneath the flatbed during the layout/welding phase. Did that get eliminated when you bolted it down?

What are you planning for the camper?
-Chris

 

[Rusgo]

That is a really nice looking flatdeck you have in the making Mr Rusgo. It will be interesting to see what you put on top of it. Cheers, Chilli...

Thanks. It's a bit slow going but making some progress.

Took off the stout rear bumper. It's too narrow. Going to cut the brackets off and weld new ones on for the 86 F350 next to it. Saddlebag gas tanks had to go to. Going to make some oversized high cleanance aluminum ones to take advantage of the new frame width.

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[Rusgo]

Very cool start. Sounds like your scoring some goodl materials off craigslist. Much better luck(skill) than I ever have!

Looks like you had some 2" square underneath the flatbed during the layout/welding phase. Did that get eliminated when you bolted it down?

What are you planning for the camper?
-Chris

Craigslist is tough. Hardly ever find anything but I've been searching for a year, travel far to get stuff, and change plans based on what I find.

2" square tube was helping keep things level! So tough getting everything to stay in place.

Had a big yacht builder in Port Angeles Washington list a bunch of thick fiberglass reinforced honeycomb core because they went to a different size. Got it for 70% cheaper than their wholesale price!

In Bend Oregon an old guy had some odd invention he was working on a decade ago but gave up. Had a ton of old left over 3/16 t6 angle aluminum I got for 20% of retail.

I'm not rich so really appreciate saving $1000s.

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[Rusgo]

Welded the underside of the bed and cut a few notches for frame clearance and plated over the openings

Extended the frame back and up 2' for length and departure angle.

Used a ratchet strap and thick sqaure tube to clamp the cross beam in place and make everything perfectly square.

.

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[Rusgo]

Basic plans are a super durable and capable rig with a cabover camper that will last forever.

Will want to be able to exist away from civilization for weeks or months and be capable of extreme cold weather comfort/operation.

Camper backbone is 2x4 1/8" steel. Structure frame will be angle and tube 3/16 aluminum. Composite panels will be bonded to the outside of the aluminum frame. Aluminum skin will be bonded to the panels, and aluminum angle outer corner to sandwich everthing together.

Walls will be 3" thick and double insulated.

Main camper body will be 10' long, 7' wide and 7' tall. Cabover adds another 4' in length.

Will have dual input fridge, solar, shower, toilet, propane for multiple redundancies, marine water heater for cabin heating and coolant heat scavenging option, room for lots of gear, double paned windows, solar shower, twin split system, etc etc.

Want it to be completely livable.

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[chilliwak]

Wow that sounds like an extremely tough and weather ready project Mr Rusgo. Good thing you got the materials cheap. Keep up the good work. Cheers, Chilli...?

 

[vargsmetal]

Awesome truck and awesome progress on the camper. I spy a Vulcan welder, which one is it and how do you like it?

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[Rusgo]

Awesome truck and awesome progress on the camper. I spy a Vulcan welder, which one is it and how do you like it?

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Thanks man. Hoping to get addicted to working on it. That's the only way I'll finish it.

It's the omnipro multiprocess. The "nice" one, haha. Seriously though, nicest easiest welder I've ever used. Like it more than the Lincolns. Nice build quality, consistent operation, lots of material options, simple and efficient settings menu, works well on 110v and 220v.

Ask me again after I've tried to mig aluminum.

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[Rusgo]

Need some expertise!

These are the composite panels in question.

Surplus 30mm honeycomb panels from a yacht builder with a fiberglass weave on both sides. They will be bonded to the outside of the aluminum camper frame, then 1/16 aluminum sheet will be bonded on the outer side of the panels as an exterior skin.

I'm thinking of using a fiberglass epoxy with good aluminum bonding characteristics. Might be asking a lot of it. A Sikaflex type product might work for the frame side of things, but the aluminum sheet side needs to be more spreadable.

Suggestions?

Progress update coming soon.

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[BajaSurfRig]

Keep the updates coming your rig/ camper is going to be epic!

 

[chilliwak]

Need some expertise!

These are the composite panels in question.

Surplus 30mm honeycomb panels from a yacht builder with a fiberglass weave on both sides. They will be bonded to the outside of the aluminum camper frame, then 1/16 aluminum sheet will be bonded on the outer side of the panels as an exterior skin.

I'm thinking of using a fiberglass epoxy with good aluminum bonding characteristics. Might be asking a lot of it. A Sikaflex type product might work for the frame side of things, but the aluminum sheet side needs to be more spreadable.

Suggestions?

Progress update coming soon.

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I have an aluminum thin sheet covering for my camper. Initially I used ordinary construction adhesive for the skin and all the structural stuff. I later went to a sika product because Sika allows for a lot more flexibility. I think you could use Sika for everything. Check out my build thread for more info. Cheers, Chilli.. ?

 

[ClovisMan]

There is a product from 3M called panel-bond. It is used in the automotive world to attach body panels to the internal framing/ Probably be good to attach your honeycombs to the framing and the aluminum to the panels.
https://www.amazon.com/3M-Adhesive-Manual-Applicator-Sticker/dp/B00KSF9TCW