C5500 TopKick 4x4 Crew Cab Build

[NeverEnough]

Some of the posts on Steel Soldiers pointed to Holland. I found this:

http://ww1.safholland.us/sites/usa/en-US/products/couplingproducts/pintlehooks/Pages/PH-T-60-AOS-L-8.aspx

They have a bunch of swivel setups. The specs on this one seemed most reasonable. What do you think? I have no idea where to buy one. The only swivels in the local Henderson Wheel catalog are the big spring ones. Maybe they could order it in.

 

[jesusgatos]

Well, I remember reading that some of the military pintles are rated for up to 40,000lbs. I think that might be on the 5-ton trucks? Pretty sure the stock pintle on deuce and a halfs are rated for at least 20,000lbs? Dunno, it's been a while since I looked at the specs, but I remember reading all about it on steelsoldiers. I would strongly recommend buying mil surplus though, as opposed to buying anything new. The swivel assembly on my deuce and a half looks a LOT beefier, and you'll save a bundle of cash. Would be shocked if a pintle off a deuce or a 5-ton cost you more than $25. Start by calling Boyce Equipment. They're one of the bigger surplus dealers, and they're in Utah. Might even be able to tell you what the different models are rated for, but if I was you, I'd do that research on steelsoldiers first.

 

[Ozarker]

I have been in your shoes. You need to look at this build from two directions. One is to buy a truck camper big enough to do what you want. And start using it in about 7 days. Or plan and design and build for a year. Or more. Just think of all the missed times. Many of the experts on the site will admit that most people spend all their time planning for the perfect rig that never happens. Buy a camper and start camping is my thought. You have the perfect truck for the biggest lance camper. Add some aluminum boxes and your can be camping next week end. OH don't forget that your custom build is going to cost you 3x or 4x as much as the BIGGEST Lance.

Very good point and the same holds true for any yacht, build for a year and usually longer to the actual finish or buy and go, the cost is about the same.

And obviously this thought was from waaay back there. The build is fantastic. You'll have a very nice land yacht when you're done.

 

[jesusgatos]

Been stuck in purgatory (build-up in progress) for two years now. In a lot of ways, it's like my life is on hold. In reality though, time is just passing, and sure I would rather be on the road already. But in the end, I think it will be worth it. Like most things, it all comes down to time and money...

 

[NeverEnough]

Very good point and the same holds true for any yacht, build for a year and usually longer to the actual finish or buy and go, the cost is about the same.

And obviously this thought was from waaay back there. The build is fantastic. You'll have a very nice land yacht when you're done.

Glad you're liking the build. It should get more interesting in the coming weeks.

 

[NeverEnough]

Been stuck in purgatory (build-up in progress) for two years now. In a lot of ways, it's like my life is on hold. In reality though, time is just passing, and sure I would rather be on the road already. But in the end, I think it will be worth it. Like most things, it all comes down to time and money...

There are many type of roads and adventures, and building something of your own design and creation is one of the best, IMHO. I've been fortunate to enjoy many adventures in a lot of different places, but I've had just as much fun tackling projects that those around me said were best left to somebody better qualified or with more experience, even when they crash and burn (who doesn't like watching a good crash and burn?).

Besides, if your build wasn't taking so long, you'd be out on the road all the time, making it far less likely you'd be sharing your knowledge on this board! So take your time.......:coffeedrink:

 

[jesusgatos]

Yeah, I agree for the most part. I've just spent so much time designing/building things that I've had to swing back towards the middle to find a healthier balance. There was a time when I was so busy building off-road vehicles that I never seemed to have time to go wheeling! So these days I'm focusing more and more on design, and outsourcing stuff whenever it makes sense - like laser-cutting sheetmetal parts. Perfect example. Saves me a whole lot of time AND I end up with better parts than I could have made myself.

Oh, and watching something crash and burn sucks when it's your money going up in flames.

 

[jayshapiro]

suggestions

Hi,

Glad to see the build is going so well.

A couple of quick suggestions:

Lockers - I suspect you'll hit your limit far before you hit your trucks limit in terms of needing a locker, but if you decide to go down that road, definitely contact Ron Turner at Tulsa Truck. They put on my meritor front axle, and redid my rear when we stretched it out. I am 100% convinced (after much research) that there is nobody in this country who knows more about big truck axles than Ron's guys, and their incredibly professional to boot.

Hitch - since your trailer load is going to be light, and you're planning on taking it off-road, I'd definitely suggest the Lock-and-Roll (what I have) or even better the Max Coupler. Both can be sourced by Mario at Adventure Trailers, who knows more about off-road hitches than you or I will ever want to.

My biggest challenge with the trailer was just seeing it. The few times we took the AT behind the EcoRoamer it completely disapeared from my mirrors. Plus, the length is so short compared to your wheelbase, that it jacks VERY fast when reversing. It can be done, but takes some getting used to.

Good luck & keep up the great progress!
Jay.

 

[NeverEnough]

Lockers - I suspect you'll hit your limit far before you hit your trucks limit in terms of needing a locker, but if you decide to go down that road, definitely contact Ron Turner at Tulsa Truck. They put on my meritor front axle, and redid my rear when we stretched it out. I am 100% convinced (after much research) that there is nobody in this country who knows more about big truck axles than Ron's guys, and their incredibly professional to boot.

Based largely on what I'd read about your experience with Tulsa, I contacted Ron early on about doing a 4x4 conversion on a crew cab Isuzu when I was exploring that option (hoping to keep the wheelbase shorter with a cabover). He was extremely knowlegable and forthright. His candid opinion, combined with a few others, helped me come to peace with accepting the limitations, and advantages, of the traditional US cab/chassis configurations for what I was trying to accomplish. And I've decided to see how I do with the limited slip for now.

Hitch - since your trailer load is going to be light, and you're planning on taking it off-road, I'd definitely suggest the Lock-and-Roll (what I have) or even better the Max Coupler. Both can be sourced by Mario at Adventure Trailers, who knows more about off-road hitches than you or I will ever want to.

I just came back from the shop fabricating the trailer and put my hands on the pintel/lunette assembly they ordered in for me. I didn't need a slide rule to figure out that it is WAY overkill for what I'm doing. However, since the trailer frame now has a receiver, it will make it easy to swap out couplers as needed. I'll order up a Max Coupler, but probably hang onto the pintel in case I need to haul a howitzer somewhere (neighborhood avalanche control work?).

My biggest challenge with the trailer was just seeing it. The few times we took the AT behind the EcoRoamer it completely disapeared from my mirrors. Plus, the length is so short compared to your wheelbase, that it jacks VERY fast when reversing. It can be done, but takes some getting used to.

AMEN! Last fall I was pulling my 16' enclosed cargo trailer behind my 40' Funmover in Southern Utah, doing about 65mph. It came off my hitch, and rubbed away the safety chains. I had NO IDEA anything had happened until it decided to pull out from behind the rig and try to pass me! Fortunately, there was no oncoming traffic and it had the good sense to crash itself on the other side of the road while tipping onto its side. That's when I realized a winch would be handy! I actually think it was trying to get back at me for denting it up repeatedly with the safety lock plates of the Funmover's lift gate while pinching it trying to back up. It happened OFTEN, and I never heard or felt a thing.

Yes, the Funmover had a back-up camera. After several trailer mishaps, I made a habit of periordically monitoring the camera while pulling our boat on the highway, half expecting to see nothing but a trailer tongue and some tattered fiberglass hanging from the bow strap.

I'm hoping that a shorter, lighter rig will at least let me know when the damage is starting, rather than find out when I've stopped for gas.

Good luck & keep up the great progress!
Jay.

Thanks, and I trust your rig is back on the road?

 

[NeverEnough]

Goodies arriving every day

My collegues poke their heads in my office every day now, alerting me that another part of my "space shuttle" has arrived. Today my range arrived, a Spinflo Triplex:

Not an easy item to come by, but worth the wait. Far better build quality than the conventional US products.

 

[NeverEnough]

I love my truck!

The truck is MOSTLY done. The remaining tasks are: 1) mount front-end leveling jacks (all of the custom jacks from Reico Titan arrived this afternoon!); 2) Fabricate the "on-the-road" supports for the propane and battery assemblies; 3) Install the spare tire holder under the rails behind the rear axle; 4) Fab and install the crawl-through door; 5) Trick out the cab interior (sound proofing, carpet, seats, AV, etc.). Items 1-3 will be finished up next week, now that the jacks are here. The rest will be worked on while we build the box.

I'm digging the fact that my camper and truck can lead their own lives when necessary. I loaded the interior wall and ceiling panel crate on her today, along with a pile of other stuff to ferry over the shop we've set up for the camper build.

Almost all of the camper components have arrived- we've just been waiting for Plascore to manufacture the panels we spec'd out. The factory called today to inform me that they'll ship on Tuesday.

We finally had success with an aliphatic urethane coating for our exterior skin. And it did extremely well with our "beat the SH#$%%T out of it" testing.

There's a lot of material options for building a camper box, but since I have a habit of "contact" driving, I'm psyched to be building a box out of something that I can beat with metal objects with complete abandon.

 

[ersatzknarf]

Hi NE,

Have been quietly following along on your project and it looks like you are going to be very happy in the end.

I have also found the various panel suppliers not overjoyed to help with supplying panels for a camper box project . . .

How has Plascore been to work with in terms of a one-off order, do you think ?
(I noticed that they are only about three hours or so from me.)

Will they be supplying the outside edge and corner pieces, also ?

I have been hankering to build a composite box with all the features laid out where we want them and as few compromises as possible. Going with a composite-only design is very attractive.

Almost all of the camper components have arrived- we've just been waiting for Plascore to manufacture the panels we spec'd out. The factory called today to inform me that they'll ship on Tuesday.

We finally had success with an aliphatic urethane coating for our exterior skin. And it did extremely well with our "beat the SH#$%%T out of it" testing.

There's a lot of material options for building a camper box, but since I have a habit of "contact" driving, I'm psyched to be building a box out of something that I can beat with metal objects with complete abandon.

 

[NeverEnough]

Hi NE,

I have also found the various panel suppliers not overjoyed to help with supplying panels for a camper box project . . .

How has Plascore been to work with in terms of a one-off order, do you think ?
(I noticed that they are only about three hours or so from me.)

Will they be supplying the outside edge and corner pieces, also ?

I think it's just a matter of the proper expectation. Anything in low volume is expensive. There are plenty of "stock" panels available, but I think the lack of enthusiasm comes from being asked to produce something custom, which is not what manufacturers are about. In addition, this build is a beneficiary of a larger composites project- on it's own it would've been difficult to justify. Plascore is a very good company, probably the best US honeycomb core company. They only manufacture panels, so I had to get pultrusions from a different source. You'll see more in the coming weeks, but I'm not relying on pultrusions for corner joints.

 

[ersatzknarf]

Hi NE,

Thanks. Very glad that you like Plascore. Yes, special orders are not always the economical way to go. I should have said, a small order of "standard" panels...

I see about not using composite extrusions for the panel edge and corner joints. I do like that method, but also like the use of alloy "L" pieces glued to both edges; the composite extrusions being of more interest.

Looking forward to how this is coming together ! ! !

 

[Jarek M]

:drool: