2007 Silverado - Buy Once, Cry Once: 1-tons, 40's & a Custom Camper
- Thread starter Andrew_S
- Start date
Mekcanix
Camper
I have a 5 gallon pail I have had for gotta be 30 plus years. Call it the Magic Bolt Bucket cause I always find the bolt I need in it. I have SAE bolts in designated boxes on the shelf, but those are new and dont mix with the bucket nopeThat kind of fabrication is more dangerous as well. Always worried about the cut off wheel coming apart.
I like your storage area for all your extra bolts. When I was a kid I used Folgers Coffee cans. I bet I probably had about 20 of those full to the top.
Andrew_S
Observer
That kind of fabrication is more dangerous as well. Always worried about the cut off wheel coming apart.
I like your storage area for all your extra bolts. When I was a kid I used Folgers Coffee cans. I bet I probably had about 20 of those full to the top.
I've adopted to wearing my Papr Miller hood whenever I'm grinding/welding now. So the safety side is less of a worry.
Oooof, the criticism cuts deep on the nuts and bolts haha. I usually do a big bench clean at the end of a project, but this one has spiralled for a bit too long. I've got several misc hardware solutions, because I'm a closet hoarder...
Starting with my previous post, random hardware from the current project spread across the bench.
Followed by misc stuff in dog dishes laid out around the garage,
Then it eventually gets categorized and stored in a dedicated tool box which is almost entirely comprised of spare stuff, lights, fuse, brackets, end cuts, hardware, etc.
But out of desperation today, I can now say I'm the proud owner of a magic bolt bucket as well, and I confirmed it works later in the afternoon. Thanks for the tip!
After seeing the passive-aggressive comments this am, I folded to peer pressure and did a bench clean first thing...
Then back to it, started cutting up this UHMW for isolation strips between the deck and frame rails.
Nice stuff to work with.
Next up was an overly ambitious project. Since we aren't running a headache rack (space considerations for camper), I've opted for a bump board at the front of the deck when loading the camper.
As soon as I started the first cut, I knew I was committed and instantly regretted this design choice. 3/8" plate is a bit of a bear with my rudimentary fab tools.
Several hours later...
Then on to the arduous task of welding out all 50k joints on this thing...
And I didn't feel like I had quite wasted enough time on the bump board, so I opted to drill a bunch of plug weld holes in it as well - love drilling holes....
Ended up getting about half the top welded out, going hard in the paint tomorrow on this.
Last edited:
ITTOG
Well-known member
Impressive, a tool box for bolts! I can't imagine a 5 gal bucket for bolts. It would suck when you need that bolt at the bottom and you had to pour everything out. Dang, I passively took you away from building but it sure did clean up nice.
For rudimentary tools that bump board looks nice in the pictures.
For rudimentary tools that bump board looks nice in the pictures.
Andrew_S
Observer
Thanks, way too much time into one piece, especially considering no one will ever see it once the campers on...
Now the trick is keeping the bench clear.
Big day today. I'm calling this a milestone; this thing officially has driveshafts!
1350 front 2.75" heavy wall & 1480 rear 4" heavy wall, both with extra slip.
Beef, stoked on these custom units.
Started immediately setting up the rear and sorting out my angles.
Both shafts will have approximately 1.5 °, perfectly within spec.
Need to sneak the exhaust over slightly to make room for the steady bearing. Reworking the hangers a bit with the torch.
This might be the best $25 I've spent on the truck in recent memory.
These old cab pressure relief vents were so rotten and allowing water in.
OE GM parts, 2 days from ordering and dirt cheap. It's kind of nice owning something new enough that the manufacturer still has parts available.
Another multi-day effort, from this:
To this:
Then paint, I have to say these might be one of the more awkward things to paint.
Now the trick is keeping the bench clear.
Big day today. I'm calling this a milestone; this thing officially has driveshafts!
1350 front 2.75" heavy wall & 1480 rear 4" heavy wall, both with extra slip.
Beef, stoked on these custom units.
Started immediately setting up the rear and sorting out my angles.
Both shafts will have approximately 1.5 °, perfectly within spec.
Need to sneak the exhaust over slightly to make room for the steady bearing. Reworking the hangers a bit with the torch.
This might be the best $25 I've spent on the truck in recent memory.
These old cab pressure relief vents were so rotten and allowing water in.
OE GM parts, 2 days from ordering and dirt cheap. It's kind of nice owning something new enough that the manufacturer still has parts available.
Another multi-day effort, from this:
To this:
Then paint, I have to say these might be one of the more awkward things to paint.
Andrew_S
Observer
These turned out great, just waiting on some isolators and I can put them together.
I spent quite a few hours getting my driveshafts and pinion angle absolutely dialled in.
I had to look at some more diagrams to understand proper geometry for a 3-joint shaft.
The first part is set at .05*, the second is dialled in a 2* on the nose, and the pinion angle matches the steady bearing perfectly.
After measuring about 20 times, I set out to make my new steady bearing mount. Fully boxed 3/16" plate.
After that, I burned in my perches and shock mounts.
Coat of paint on everything so I can get it together tomorrow.
Spent the last 3 hours of the night welding my life away on this thing.
I spent quite a few hours getting my driveshafts and pinion angle absolutely dialled in.
I had to look at some more diagrams to understand proper geometry for a 3-joint shaft.
The first part is set at .05*, the second is dialled in a 2* on the nose, and the pinion angle matches the steady bearing perfectly.
After measuring about 20 times, I set out to make my new steady bearing mount. Fully boxed 3/16" plate.
After that, I burned in my perches and shock mounts.
Coat of paint on everything so I can get it together tomorrow.
Spent the last 3 hours of the night welding my life away on this thing.
Andrew_S
Observer
Yesterday was a great day for progress.
Started out with some satisfying final assembly stuff. Really stoked on this mount, it was easy to get done and came out super strong.
Took my old leafs apart to confirm I was glad I put this other pack together. Significant wear at the end of the springs and they likely didn't have much life left.
Final assembly on the new to me leafs. All new isolators and zinc pads.
So much better
Rolled this back axle underneath for hopefully the last time,
I'm going to need to invest in a bigger jack sooner than later.
I learned a valuable lesson yesterday regarding painting these air bumps. I picked these up second hand and they had some rust on the outside when I bought them. I thought I would clean them up and paint them to keep the rust down. Terrible idea, or maybe terrible paint - the one that's almost bare fought me every mm of the way.
I think I'm just going to antiseize the snot out of them on final assembly. Anyway, upper limit strap mount done, decided to make my own rather than use what came with kit. Air bump height set and welded in solid as well.
So nice to see this stuff all coming together.
I spent the remainder of my evening welding my life away.
Good thing it isn't any wider, might just need a bigger garage...
Started out with some satisfying final assembly stuff. Really stoked on this mount, it was easy to get done and came out super strong.
Took my old leafs apart to confirm I was glad I put this other pack together. Significant wear at the end of the springs and they likely didn't have much life left.
Final assembly on the new to me leafs. All new isolators and zinc pads.
So much better
Rolled this back axle underneath for hopefully the last time,
I'm going to need to invest in a bigger jack sooner than later.
I learned a valuable lesson yesterday regarding painting these air bumps. I picked these up second hand and they had some rust on the outside when I bought them. I thought I would clean them up and paint them to keep the rust down. Terrible idea, or maybe terrible paint - the one that's almost bare fought me every mm of the way.
I think I'm just going to antiseize the snot out of them on final assembly. Anyway, upper limit strap mount done, decided to make my own rather than use what came with kit. Air bump height set and welded in solid as well.
So nice to see this stuff all coming together.
I spent the remainder of my evening welding my life away.
Good thing it isn't any wider, might just need a bigger garage...
Andrew_S
Observer
Well, after a lot spools and some burn tips, this thing is fully welded out and everything ground flat that needs to be.
Definitely testing the safety factor of this picker at max reach... The closer you look the worse it gets...
By some miracle, everything cleared, shock mounts, exhaust, air tank, and bumps. It was super tight but my holes all lined back up and it's now on, maybe for good?
Short list of big projects left to tackle, and then this thing will be ready for the road.
Definitely testing the safety factor of this picker at max reach... The closer you look the worse it gets...
By some miracle, everything cleared, shock mounts, exhaust, air tank, and bumps. It was super tight but my holes all lined back up and it's now on, maybe for good?
Short list of big projects left to tackle, and then this thing will be ready for the road.
Kingsize24
Well-known member
It looks damn good! Im sure that was a proud moment seeing it all together and clearing everything.
BajaSurfRig
Well-known member
Thank you for taking the time to continually upgrade this thread. Your skill and craftsmanship is admirable!! That flatbed is a thing of beauty well done!
Andrew_S
Observer
Thanks, I just can't wait to take it out in the bush and see how it rides. It should be greatly improved over the stock set up.
Thanks for this, hope the final product doesn't dissapoint. Can't wait to get started on the camper.
Maybe some 35's and a 3 link in the front? The wife and I tossed around the idea of getting rid of it but I just can't bring myself to let it go. I have a secret plan to flat tow it behind this new truck for hunting season. That will allow us to use it as our skinny trail bush rig and keep the new truck as home base.
Small update, decided to go with these rock lights for my license plate lights :
It worked out awesome,
I think I'll hook them up to a secondary exterior switch so that we can use them as surround lighting when hanging around outside by the future table at the back.
Kingsize24
Well-known member
Looks great! I used those lights on my M1102 camper and they are plenty bright for dark nights. I liked them alot as well. There is a set that has an integrated button on it sold as a dome light if you ever need. Same setup, just internal controls.
Looking excellent!
Looking excellent!
Todd780
OverCamper
Secret plan? Lol. Wifey doesn't know?
Andrew_S
Observer
^ She knows, I'm just not sure if I'm that committed yet. I did start eyeing up some flat tow packages at the junk yard the other day.
Progress is still progressing,
mock up for the driver side boxes
from cardboard to aluminum
Decided to try and learn tig welding for a portion of this project, it's super fun.
Until it's not, HF board on my little diversion was acting up.
Minimal tire poke, very satisfying seeing this vision all come together.
The boxes will be framing out my fenders for the deck as well
Tail light wiring will live inside the box protected from the elements
This is by far the most complex box. It needs a knock out for the fass system and integrated fuel door.
this took a lot of thought and templates to get it right, I needed to angle the filler neck towards the tank and downwards as much as possible to minimize the impact on the box space and keep flow restriction down.
My wife didn't think it would work and insisted on a dry run, thankfully she didn't prove me wrong this time.
I didn't get as much done as I wanted to this weekend but I'm calling it a win.
I finished up by cutting out the deck panels. I've been trying to only buy what I need for materials and I cut it really close on this aluminum sheet. I needed the scraps from these 4x10 sheets to finish my boxes on the other side.
Thanks, happy with how they turned out, great product. I have a pair of the dome lights in my other camper. They are awesome. I wish they sold the interior ones with a bit warmer of a light though.
Progress is still progressing,
mock up for the driver side boxes
from cardboard to aluminum
Decided to try and learn tig welding for a portion of this project, it's super fun.
Until it's not, HF board on my little diversion was acting up.
Minimal tire poke, very satisfying seeing this vision all come together.
The boxes will be framing out my fenders for the deck as well
Tail light wiring will live inside the box protected from the elements
This is by far the most complex box. It needs a knock out for the fass system and integrated fuel door.
this took a lot of thought and templates to get it right, I needed to angle the filler neck towards the tank and downwards as much as possible to minimize the impact on the box space and keep flow restriction down.
My wife didn't think it would work and insisted on a dry run, thankfully she didn't prove me wrong this time.
I didn't get as much done as I wanted to this weekend but I'm calling it a win.
I finished up by cutting out the deck panels. I've been trying to only buy what I need for materials and I cut it really close on this aluminum sheet. I needed the scraps from these 4x10 sheets to finish my boxes on the other side.
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