FG84 Camper Build

Amesz00

Adventurer
thats because you average insurance company regards it as a commercial vehicle
it will face high risk from its many hours on the road
when i explained its a private vehicle the computer didnt understand
So im with ken tame aswell
being in the CMCA isnt that bad, they have a good support base
and so long as you dont mind being in bed by 7 theyre a good crowd :) (thats a joke by the way)

Stu, what's in your truck? Ie is it setup as a camper, or just storage for stuff? I thought cmca only insured 'motorhomes' that were fitted out..
 

blackduck

Explorer
Stu, what's in your truck? Ie is it setup as a camper, or just storage for stuff? I thought cmca only insured 'motorhomes' that were fitted out..

its a camper up top storage on the bottom, I had to send pictures of it to qualify for CMCA membership
as i was towing a 30' van round at the time that was my home there wasnt any point going the whole live in motorhome thing
but you can live comfortably in it so long as the water lasts
 

Maninga

Adventurer
It's Home!!!!!

It's been a brilliant last couple of days. Went up last Thursday to Styromax to pick up my truck, finally got to see the finished product in the flesh. I was like a kid in a candy store seeing it, the photos don't do it justice and I'm really happy with how it turned out. Heather came up with me too, it was her first time seeing the Styromax operation and while she was interested in the project, even she got excited seeing it in person. Some glamor photos (all except 2 of mine were out of focus)

Body Closed RF.jpg

Body Open RF.jpg

Door way.jpg

Actuators.jpg

Me with Steve and John from Styromax
DSC_9884.JPG

Truck in its un-natural habitat
DSC_9887.JPG

Promotional video from them

I spent several hours with them going over the build, the process, all the little stuff and details. The highlights
- As far as they could, outside is thermally decoupled from the inside.
- 3 sets of rubber seals are used to seal the main body from the roof, 1 on the lower step, 1 flexible layer that covers the gap between roof and base, third on top of base the roof rests on.
- Actuators are mounted on sheer rivets (hopefully they'll work), so if one doesn't work it won't tear the box apart
- I found the sense of space inside to be fantastic. It's ~2.2m high inside, the roof is reflective and windows all round make a massive difference.
- The roof lifts up/down. Takes a while, but it's fun to watch.
- Rear storage area is really big. Will make good use of it

After paying the bill now came the nerve racking moment - driving the truck. The only time I'd driven it was 10 minutes over a year ago when buying it and remember, I'd only gotten my truck license specifically for this truck. My only hope was to not stall it or take out a gate/fence. Made it out alright and tentatively made our way through Brisbane traffic. Spent a good night with family.

Friday went and saw Shannon's truck (LeishaShannon). Neat looking truck, lots of tech toys in there and some good ideas I'm going to use in our build. Especially like his pantry and air conditioning. Headed off after to ATW to ask about some parts, rain and traffic were just terrible and took us 3 hours to get 100km. Stayed the night with John (whatcharterboat) and Julie in Noosaville, really nice people and a beautiful area they live in.

Saturday saw us starting off home. Went and saw a project Johns working on with his friend Brad. Talked a lot about each others trucks, including about putting an Allison transmission in mine. Thinking about it some time in the future, though may be a little out of my budget. Headed from there to Toowoomba where grandparents live, they're 93 and haven't seen them in 3 years. Good lunch with them and some relatives before they guided me out to the Newell highway, told me it'd be the best road to get to Canberra.
I have to say, still recovering from that decision. The bumps, the road, in a truck where the suspension was built for the end weight (roughly 2 tonne more than what's on it now), with the standard seating, it wasn't a fun trip. Heather had a pedometer on for most of the drive, registered 100,000 steps over the 3 days driving. Good to see some of the views along the way, but didn't have the time to enjoy it. Made our way over 2 days to Canberra to stay with Owen (SkiFreak) and Sharron. We've both got the same make/model/year truck, though his has the fancy coil suspension, mine's the parabolics. Lots of truck talk was had, true to form Owen was still talking after starting the truck on our way out to leave. It's an art form.

Monday saw us get home. Much smoother ride on the highway and very very glad to get home to our own bed and pillows. I don't think I made it an hour past eating dinner.

Fuel economy for the drive home I thought was pretty good. Even with the wind trap above the spare tyre rack and driving at 100-110 most of the way (it was a "get there as quick as possible run" rather than an economy run), got around 18l/100k's.

Now the fun begins building out the interior. We've a boat building club 10 minutes walk from my work, you rent a space from them, they have the big machines and provide the guidance/expertise around materials, working with fiberglass, working with timber and the occasional helping hand, and a number of other people working on their own projects in a big warehouse space. They've allocated me enough space to fit the truck and some workspace, for the 100/week it's well and truly worth it, especially for the teachings around fiberglass.
 
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PKDreamers

Adventurer
Wow your truck looks great.
Do you have a time frame to finish interior so you guys can get out and use your truck?
 

Maninga

Adventurer
Wow your truck looks great.
Do you have a time frame to finish interior so you guys can get out and use your truck?

Thanks. We want to get it ready enough for first real trip in May/June this year. The big stuff is probably going to be the easiest, getting the electrical and lighting right, hot/cold water and some of our other plans are going to take the longest. There'll be a couple of weekend trips in between, though moving into a house we just bought and starting renovations may come in the way. That and budget, everything we're doing from now is from savings/cashflow.

Maninga

How far down the track are you with your interior plans? This mob advertise in the Wanderer and the product looks interesting so it might be worth some further investigation
http://www.duraliteaustralia.com.au/

Haven't used it myself so can't comment.

First thing we did after getting it in our hands was start re-designing some of the internals. I think what we're going to do is start mocking it out in cardboard, figure out what works for us and start building. I'd forgotten about Duralite as a panel option, thanks, will look more at what they've got.

Other stuff still to be decided is fuel/water tank positions, storage boxes on subframe, multitude of other things really only possible once I could visualise and measure everything accurately.
 

Maninga

Adventurer
The last month has been busy. It took me a couple of weeks to figure out placement of water tanks, dimensions of pantry, countertops, seating etc.

the biggest impact on the design though was the fridge, it's a bloody big fridge, takes up a lot of space and is too deep for where I was originally wanting to put it. I thought a lot about getting rid of it, but it's bought and getting it out is a bugger. To get everything in, had to cut 200mm from each seat, leaves us with seating for 2 rather than plan of 4. Oh well.

After much back and forth, I'm putting water tanks inside. Two tanks are going in, a 150l tank for kitchen/drinking water and 240l tank for shower and hot water. Currently on order, should be here in a week or so.

I will give some mention to the space I'm renting. Docklands still has a couple of the original warehouses left, in one of them is a wooden boat building shed. They offer space, advice, help on techniques, and set aside a fair section for me to work with. Also charging me almost double what they'd been telling me for 4 months, so won't be there for long. Photos of the space.
Boatshed 2.jpg

Boatshed 1.jpg

Interior I've decided to do out of 12mm marine ply for the main structures. 6 sheets cut to width
Workspace 1.jpg

Very technical method of marking out what I'm making. Whiteboard marker and packing tape :bike_rider:

Inside 6.jpg

Inside 5.jpg
 
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Maninga

Adventurer
Some more progress, seating shell built, sink and drawers, front floor and area around bathroom. Still need to do pantry, get the countertop build (have some nice red gum for it), glue it all together, build pantry out, fibreglass bathroom and get plumbing/electrical sorted. Probably doing stuff wrong way round, but it's the way I think.

Inside 4.jpg

Inside 1.jpg

Inside 3.jpg

Inside 2.jpg

Putting this together has been fun sofar, tiring and something never done before. More progress to come in following weeks.
 
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Maninga

Adventurer
Not sure why pictures have rotated, loaded it up on iPad. Will fix when on a normal computer

Edit: Fixed photos
 
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whatcharterboat

Supporting Sponsor, Overland Certified OC0018
Not sure why pictures have rotated, loaded it up on iPad. Will fix when on a normal computer

Hi Joe
Wish you had said that before. Tried to turn my PC monitor sideways but it fell over. .... iPad is much easier to read sideways.......

Regards John
Sent from my phone sideways.
 

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