2017 F-550 Camper Build - Ground Up

[PacificNorthWestJeeper]

It's been a bit... I needed a break and the weather has been ccoolldd and my dog ate my homework....
Back on it this weekend, working on the temporary rear brake light housings..
The template for cutting out the brake light holes with the plasma cutter was awesome.
I primed them, went with semigloss black and then sprayed 2 coats of clear which on one side the clear ran.. Too cold to paint today anyway, I might fix the run later, but good enough for temporary housings.
I also got the wheel locks Cerakoted black. I could not powder coated them due to the thickness of the powder coating. Cerakote'ing them worked out perfectly....
The forecast looks like cold and snow the next few weeks so that may slow the progress.....

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[PacificNorthWestJeeper]

I had to take the tires/wheel well liners back off due to the tires rubbing when I turn the steering wheel with the air bags completely deflated... They barrrrely rubbed, but I need room not only for the tires but snow chains if/when I use them and IF I blow an air bag I need the tires to not rub (worst case scenario) so I can limp out of an area and change the airbag out.... I tore everything back apart and was able to cut back into the body another 2+ inches. I then had to make new patch panels and seam sealed them back into place. Now to wait for the seam sealer to dry and then put the liners back in place. Should have plenty of room now. Take that as a lesson from my mistake. In the pics below you can see how much further I cut back into the body. If you go back into this thread you can see when I originally did this and compare then an now... Big diff and I feel better. The seam sealing is the same technique they use for brush trucks which I learned from other builder/fabricatotion companies online.
I also got the temporary tail lights fixtures painted, wired and bolted into place. I need these because #1 I want to drive the truck around and #2 I need to take it down to a frame fabricator who will bend up my new frame section for me. I will be extending the rear of the frame 3 feet, more to come on that.
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[wfv56]

My personal experience with a diesel fuel fill line that flat is pretty negative. I’d try to add some slope if you can.

 

[PacificNorthWestJeeper]

My personal experience with a diesel fuel fill line that flat is pretty negative. I’d try to add some slope if you can.

Good Point, I was actually thinking the same. I think I will move it up 4 inches or so to give it some height, it's temporary but it would suck to have diesel spill out on me when filling it up.

Finished up the wheel wells 'again', plenty of clearance now....
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[Skinhyfish]

Good Point, I was actually thinking the same. I think I will move it up 4 inches or so to give it some height, it's temporary but it would suck to have diesel spill out on me when filling it up.

Finished up the wheel wells 'again', plenty of clearance now....
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Yes.. had a flatbed built by alumiline and I couldn't fill up because it was level. They told me to deal with it. I had a redneck way and drove up on a block to get angle for filling. So annoying!

 

[unreng]

a word of advice on the titan fuel tank strap bolts...either replace them with stock ford bolts with distorted capture nuts or double nut.
we had two straps let loose while traveling on vancouver island in June 2023 (using the thread locker provided with the tank)...the only way we knew was stopping for laundry and noticing the tank was hanging funny.
one strap caught on the driveline support, which prevented the tank from dropping to the ground.
we made it to Steve Marshall Ford, bought all of there fuel tank bolts and capture nuts, and replaced every titan fuel strap bolt in the parking lot.
we manually distorted the thread on the capture nuts and the bolts haven't moved during the ~11,000 miles to Alaska and back.

also consider extending the vent lines on the front of the titan tank.
if the truck is parked where the front is lower, the lines will slowly drip diesel.

regarding shocks - look at any of the manufacturers with adjustable compression valves (we chose IVD shocks with the adjustable compression valve).
think i see an adjustable fox for the rear?!?
once a large box is on the rear, the weight is likely going to overpower the valving on a typical shock (including remote reservoir).
we had remote reservoir kings on the front and the adjustable IVD shocks were better at preventing sway.
and the adjustable shocks help with the floatiness of an air suspension.

lastly, watch the rear panhard bar bushings. our lower bushing disintegrated somewhere before or during our Alaska trip and it caused all sorts of issues (including causing an air bag to rub thru on the chassis on a return trip from overland expo pnw 2024).
It took hours to replace the bushing with a box on the rear suspension.

i'd vote for cascadia composites for your camper...probably the best camper product on the market (and I see from the steels forum that they are practically your neighbor).

edit - what are you using for fuel filter?

Also consider installing the larger ford mirrors - https://www.ford-trucks.com/forums/1634219-102-extended-mirrors-available.html

 

[PacificNorthWestJeeper]

VERY HELPFUL AND AWESOME FEEDBACK, REPLIES IN RED BELOW. THANK YOU SO MUCH, GREAT STUFF!!! Keep it coming!

a word of advice on the titan fuel tank strap bolts...either replace them with stock ford bolts with distorted capture nuts or double nut.
we had two straps let loose while traveling on vancouver island in June 2023 (using the thread locker provided with the tank)...the only way we knew was stopping for laundry and noticing the tank was hanging funny.
one strap caught on the driveline support, which prevented the tank from dropping to the ground.
we made it to Steve Marshall Ford, bought all of there fuel tank bolts and capture nuts, and replaced every titan fuel strap bolt in the parking lot.
we manually distorted the thread on the capture nuts and the bolts haven't moved during the ~11,000 miles to Alaska and back.

REPLY: Wow, I could see that happening, I did use blue loctite on each one but now will definitely use captured nuts on top of the existing ones for insurance, thank you!!!!

also consider extending the vent lines on the front of the titan tank.
if the truck is parked where the front is lower, the lines will slowly drip diesel.

REPLY: Will do, good idea!

regarding shocks - look at any of the manufacturers with adjustable compression valves (we chose IVD shocks with the adjustable compression valve).
think i see an adjustable fox for the rear?!?
once a large box is on the rear, the weight is likely going to overpower the valving on a typical shock (including remote reservoir).
we had remote reservoir kings on the front and the adjustable IVD shocks were better at preventing sway.
and the adjustable shocks help with the floatiness of an air suspension.

REPLY: I did consider that, once the truck is fully set up the truck will be weighed on all 4 corners, shocks will then be sent back in to be tuned...

lastly, watch the rear panhard bar bushings. our lower bushing disintegrated somewhere before or during our Alaska trip and it caused all sorts of issues (including causing an air bag to rub thru on the chassis on a return trip from overland expo pnw 2024).
It took hours to replace the bushing with a box on the rear suspension.

REPLY: Will do, depending on how the alignment goes (when I get to that point) I may be making an adjustable Pandhard Bar at that point, still thinking on that.

i'd vote for cascadia composites for your camper...probably the best camper product on the market (and I see from the steels forum that they are practically your neighbor).

REPLY: Defiantly a contender.

edit - what are you using for fuel filter?

REPLY: The filter that came with the kit, nothing special.

Also consider installing the larger ford mirrors - https://www.ford-trucks.com/forums/1634219-102-extended-mirrors-available.html

REPLY: I already got them, thank you!

* This last weekend I took it for a drive around the block after adjusting the parking brakes. I have a noise (metal) now on the drivers rear side. The noise didn't occur the maiden voyage, I had not adjusted the parking brake then, I put the truck back up in the air and took off the driver rear tire. Hopefully next weekend, weather permitting, I can pull the rotor off and see what's up. Thinking a spring or something came off on that side, maybe parking brake pad out of whack? I checked the dust shield and that does not appear to be the culprit. . Just when I thought I was ready to move forward I now have to go back AGAIN and redo the driver rear parking brake set up... UGHHHHH. 3 steps forward 1 step back. lol..... How I hate going back a redoing something I thought was done...