1999 Chevy S10 ZR2 Camper build. Ideas, collaboration, insight.....

[javajoe79]

Let me start out by saying... WOW! This site is pretty awesome!!

Anyway I am in the planning stages of building my own rig out of my trusty S10 ZR2 extended cab truck. I have owned the truck since new and it has always been my adventure vehicle. I have reached a point in life where I want a rig that will go anywhere and keep me and my gal comfy. I am planning to remove to bed on my truck and build a box to go in it's place. Basically a pop top camper that has the bed over the cab of the truck and "living" quarters below. I want 4' of lift and I want to keep the roof line as low as possible. I will build the frame and shell from aluminum tube and sheet aluminum riveted with solid rivets to the frame. I own a full fab shop and my full time job is working on race cars, fast street cars, and other fabrication work. I plan on building everything myself but also utilizing existing parts where needed, which brings me to my first problem to solve.

How to make the top raise up 4'? I want it to be either electric or air operated, with manual override in case of lack of air or electricity. Basically I want to be able to fully lift the top from the drivers seat, crawl into the box from inside the truck and get in bed.

My initial thought is to utilize the mechanism from a salvaged pop up camper.

A few other parts of the build that will be essential to me and will be incorporated in the future.

1. Cummins 4BT diesel engine swap

2. Wheel wells built to accept 35" tires at standard ride height front and rear.

3. 12v power with at least 2 house batteries

4. water tank

5. fishing rod and rifle storage

6. stove

7. solar panel

and much more late

I will be removing the bed from the truck soon and beginning the initial fabrication of the "flatbed" that will become the base of the camper. Looking forward to reading some more build threads for ideas and looking even more forward to hitting the road or trail with my own build. Hope to have a basic weather proof box that I can sleep in, by spring with the complete outfitting coming later as a work in progress.

Here is me on facebook if anyone cares https://www.facebook.com/ChrisCoffey79

and here is the link to my shop's page https://www.facebook.com/CoffeyFabrication?ref=br_rs

 

[T.Low]

Sweet. The world needs more mid size Chevy overlanders. :ylsmoke:

 

[javajoe79]

Sweet. The world needs more mid size Chevy overlanders. :ylsmoke:

I guess I actually posted this in the wrong section... lol T.Low do you have a build thread? I love Astro Vans!

 

[javajoe79]

Been sorting through alot of pics and ideas and I think I will head in the direction of hard sided. The XP Camper V2 is just about exactly what I want. Lifting only one end simplifys things a good bit.

 

[Buddha.]

Subscribed

 

[javajoe79]

So I have finally started on this build. I got the bed and rear glass removed to start with. Then I ordered some baja style front fenders to help fit 35" tires as well. They should be in this week. Then I got to work on the frame. So far I have a basic floor frame and I have all the material on hand to build the rest. The box will stick out a good bit on the sides of my S10 but I didn't want to compromise fitting a queen bed sideways and in the future I may end up putting this camper on a larger truck. Not sure on height yet but I am thinking about 90" from bottom of camper to the roof. It will hinge at the front and have the door on the back and be totally hard sided. Construction of the body and frame will be almost entirely aluminum square tube and sheet. 2" x .120" tube for the main frame with 1" x .062" for triangulation and for the roof structure. I will skin the corners in .062" sheet so they are a bit sturdier and I will skin the rest with 18 or 20 ga. The floor will probably be .095"

Specs will be as follows. 84" wide and around 145" long. Queen bed entirely over the truck cab. There will be wheel wells built into the camper body that will fit 35" tires at stock ride height for my ZR2. I may end up with different wheels to widen the stance a bit in the future but for now the stock wheels will work. On that subject I am on the hunt for a narrow 35" AT or MT tire. Something at most 10.5" wide. Not many options out there so if anyone has any leads please speak up. Diesel engine swap. Probably a Cummins 6BT in stock from to keep it simple and reliable. To go along with the diesel engine I will have a diesel stove, heat and water heater and I will tie that all in to the main fuel tank as well as the engine coolant for preheating in cold weather and for hot water courtesy of the engine at times. I think rather then an on board generator I will use the engine and a large alternator or alternators to charge the house batteries and run electronics. I hope to eventually have AC and fridge as well.

My main goal at this point is to build a weatherproof box with a bed and a door. This will also have a pass through built into the truck cab.

Looking for recommendations on the following:

Tall and narrow 35" tires.

A good sealer for the body panels.



So yeah.... here are a few pics...

 

[SpaceWrangler]

if those are 15" wheels, good luck finding a narrow 35" tire.

a 16" wheel will give you a few MT options. ..couldn't find anything in an AT. the SSR is what i'd go with of the choices below.

Bogger 35x10.5R16
34.8 x 11.12, 66lbs, skid depth 28/32

TSL Q78-16LT
35.5 x 10.8, 66lbs, skid depth 27/32

SSR 35x10.5R16
35 x 11.6, 70lbs, skid depth 21/32

LTB 34x10.5-16
33.6 x 10.7, 59lbs, skid depth 22/32

Special Service TSL 9/34-16LT
33.8 X 9.1, 56lbs, skid depth 27/32


i have no camper fabrication experience, so i cant comment on what the best sealer is.

 

[ToyotaRoamer86]

Whats going with this awesome looking build?

 

[javajoe79]

I started another build thread as this one is in the wrong section. Here is the other thread.. http://www.expeditionportal.com/forum/threads/144522-1999-Chevy-S10-ZR2-Camper-build/page3

if those are 15" wheels, good luck finding a narrow 35" tire.

a 16" wheel will give you a few MT options. ..couldn't find anything in an AT. the SSR is what i'd go with of the choices below.

Bogger 35x10.5R16
34.8 x 11.12, 66lbs, skid depth 28/32

TSL Q78-16LT
35.5 x 10.8, 66lbs, skid depth 27/32

SSR 35x10.5R16
35 x 11.6, 70lbs, skid depth 21/32

LTB 34x10.5-16
33.6 x 10.7, 59lbs, skid depth 22/32

Special Service TSL 9/34-16LT
33.8 X 9.1, 56lbs, skid depth 27/32


i have no camper fabrication experience, so i cant comment on what the best sealer is.

Panic fan? :beer:

Yeah I will eventually go with a 16" or bigger wheel. That will probably happen when I swap axles on this thing. Probably going for ford 9" front and rear as I am pretty familiar with them.