80s FWC Keystone Floorpack question - how to reduce weight

[Philos64]

I just picked up an 80s Keystone ($500) and weighed it when I got it home. It weighs in at right around 1200 lbs. Does anyone know what the original weight of a mid- to late-80s Keystone was?

Regardless, I would like to drop at least 300 of that 1200 lbs. It's riding in a 1999 1/2 ton Chevy Silverado, 4x4, with a 4.8 L V-8. The camper, truck, me and nothing else are about 200 pounds under the GVWR.

I drove it home to Laramie, WY from Arizona during windstorm on I-25, and the truck tracked really well, and had no noticeable roll during gusts. (17.5 mpg on the way down, 13.8 on the way back, with a headwind)

I want to see if I can't lose some camper's weight.

A previous owner modified the floorpack to fit a newer pickup.











The floorpack is oriented strand board (OSB) which weighs about 52 pounds per 1/2" 4' x 8' sheet. There is approximately 3 and 1/2 to 4 sheets making up the floorpack. He left some of the original plywood in as well. All the cabinetry is 1/2" OSB with a veneer.

Having spent a bunch of hours looking at different builds of FWC campers on this site and others, I found a good picture of a bare aluminum frame. It looks to me like the full weight of the camper rests on the forward (with window to pickup cab) and aft (where the door is) walls, and on the bottom rails of those two walls. Is this how the frame is designed?





If so, is there any reason I couldn't tear out all the OSB and plywood and use fiberglass, epoxy, and 3/4" nida-core for the whole floorpack? I'm talking about the floor and sides that hang over the truck bed rails, not the fore and aft walls.

the cheapest place I found for nida-core is Merritt Marine Supply, where 3/4" nida-core is $64.58 a sheet.

I'm interested in informed opinions, suggestions, and speculations. Should I just bag replacing the OSB and get some $235 Hellwig helper springs (Model # 61902) and know I'll be over my GVWR by 200 or 300 pound?

Also, what else could I do to help lose that 300 pounds?

Thanks...

Jeff
Laramie, WY

 

[evanasby47]

Cut the fat

Jeff,
Although I am on several other website forums, this forum keeps deleting my replies. So this is a test.

 

[evanasby47]

testing quick reply

 

[evanasby47]

Go to Wander the West

Jeff,
It deleted my reply again. Post your question on Wander the West website. I'll reply there.
Boonie
Brighton, CO

 

[evanasby47]

cut the fat

Jeff,
I'll try on more time. From the pictures the previous owner has replaced or covered up the original fabric ceiling with plywood paneling (extra weight). It looks like the forward box is framed with 2x2 and covered with OSB. This is overdone and heavy. Although I have a Grandby not a Keystone it still looks like the previous owner has replace and/or created cabinets and drawers that were not part of the original design. I have to assume that he may have used the same overkill construction that I think is the root of your overweight rig. Also with changes to the floor pack, did the previous owner double up on any of it?

I am in the beginning process of rebuilding my Grandby and am currently the aluminum skeleton you referenced with all the cabinets and appliances stacked in my garage. I have weighted everything that is going back into the camper, because I will also be on a 1/2 ton. My weight comes nowhere close to your #1200 so again I am suspecting the changes made by the previous owner.

As for the floor pack, the weight of the "camper" is primarily carried by the front and rear walls, however, the weight of the cabinetry, appliances, water tank, furnace, etc is resting on floor pack.

Bottom line, try to find a similar camper in your area and compare it to yours, which I think will allow you to return it to original, or allow you to evaluate the construction of the cabinetry.
Boonie
Brighton, CO

 

[ripperj]

I'm not sure I would go through all that effort to lose minimal weight. Focus on beefing up your suspension and make sure your brakes are in good shape

Sent from my Passport

 

[Philos64]

Thanks for the suggestions. I was going to redo the cabinets anyway, so I'll start with that. After discovery, I'll consider what to do next. I know the roof lift was modified and the only reason I can lift it is that I'm a big guy and fairly strong. I have to lift the front from the outside and put a 2" x 2" in place before lifting it with the modified lift while lying on the upper bunk. Struts are needed at minimum. Jeff...