Flippac build-out
- Thread starter Arclight
- Start date
Arclight
SAR guy
I went ahead and drilled holes in the Flippac and installed rivnuts made for composite materials. The ones I used are from McMaster-Carr, part #97217A410. I made an installation tool instead of buying one for $65. The tool is just a steel spacer with a 5/16" hole in it, two greased washers and a 2" 1/4-20 grade 5 bolt. To use, thread the rivnut up to the spacer, insert fully into the hole and slowly tighten with a wrench until very snug. Do not use an impact or you might overtighten and crack the glass.
I taped up the fiberglass, measured and used a new size 'X' drill as recommended. Since you're hand drilling, you could probably go a few thousands smaller:
I recommend testing your installation skills on a scrap piece of material before attempting on your shell:
And here is the finished mount:
With the awning pinned on (the other side of the door hinge is bolted to the extrusion):
Front view, with the new flood lights installed:
All set up:
A couple of notes:
1. I applied some RTV to the rivnuts before installation to make sure they seal. Use only clear RTV - the black stuff will stain your gel coat.
2. After you set the rivnuts, make sure you can thread a bolt onto them by hand. If there is any resistance, STOP. If you crossthread a fastener, you are screwed, as the rivnut will probably spin and get loose, preventing removal of the bad bolt. Chase the threads with a tap if they got distorted during install.
3. The door hinge works great, and I can remove/attach the awning in about 2 minutes by myself. The tab for the off-road lights also works well. Be sure to measure the angle that you want the mounts to sit at before doing your bends. It probably isn't 90 degrees.
4. The rivnuts have a flange that will stick out of the fiberglass. I made a small gasket out of rubber to make it sit snug all the way around.
Arclight
I taped up the fiberglass, measured and used a new size 'X' drill as recommended. Since you're hand drilling, you could probably go a few thousands smaller:
I recommend testing your installation skills on a scrap piece of material before attempting on your shell:
And here is the finished mount:
With the awning pinned on (the other side of the door hinge is bolted to the extrusion):
Front view, with the new flood lights installed:
All set up:
A couple of notes:
1. I applied some RTV to the rivnuts before installation to make sure they seal. Use only clear RTV - the black stuff will stain your gel coat.
2. After you set the rivnuts, make sure you can thread a bolt onto them by hand. If there is any resistance, STOP. If you crossthread a fastener, you are screwed, as the rivnut will probably spin and get loose, preventing removal of the bad bolt. Chase the threads with a tap if they got distorted during install.
3. The door hinge works great, and I can remove/attach the awning in about 2 minutes by myself. The tab for the off-road lights also works well. Be sure to measure the angle that you want the mounts to sit at before doing your bends. It probably isn't 90 degrees.
4. The rivnuts have a flange that will stick out of the fiberglass. I made a small gasket out of rubber to make it sit snug all the way around.
Arclight
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washington taco
Explorer
Pretty slick build!
dman93
Adventurer
Arclight - I think this will be my next mod! I could have definitely used some shade this past weekend in Red Rock Canyon and Alabama Hills. I'm a little unclear on the use of rivnuts. I assume the upper mounting screws are "blind" so the rivnut for those is inside the steel tube. So did you need a special composite rivnut just for the outer surface ('glass)? But the lower screws go through the 'glass and are accessible on the back side, so did you just use nuts there?
By the way, since you've added quite a bit more weight with your FP compared to your previous shell setup, how is your suspension holding up? My last trip involved more mountain highway driving and with me plus 2 passengers, with the extra stuff that includes, my stock T100 was tail-dragging a bit, and definitely didn't feel as settled in the turns.
-dman93
By the way, since you've added quite a bit more weight with your FP compared to your previous shell setup, how is your suspension holding up? My last trip involved more mountain highway driving and with me plus 2 passengers, with the extra stuff that includes, my stock T100 was tail-dragging a bit, and definitely didn't feel as settled in the turns.
-dman93
Arclight
SAR guy
I went with rivnuts because it would have been tricky to put a through bolt into the upper tube and not have it hit anything on the other side. The driver side isn't a problem, but it's got the Aluminum/fabric attachment thing for the hammock on the passenger side, and I really didn't want to drill into that. Once I did that, I just decided to put them on the bottom too, so that I could unscrew it without someone helping me.
One note: The ARB awning is too fat, at least with my setup, to clear the crank during opening. So I moved it over to the passenger side. I still put all brackets on all four corners, as I wanted the "rain gutter" channel for mounting a removable rack later, and the mount up front for my floodlight.
On the suspension, I am sitting about an inch lower in the rear now.
Arclight
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Arclight
SAR guy
At the Desert Rendezvous last month, Dave Bennett had a neat curtain mod in the back of his Flippac. I decided to do something similar.
First, I looked into curtains, and discovered that 45" tall curtains are a standard size. You may not always see them at Target or Walmart, but they are available. Fortunately, Amazon has a few to choose from. I also ordered a roll of 1/4" bungee cord to hang the curtains from, some bungee cord hook ends, and a bag of heavy-duty nylon boat cleats.
Here is the attached curtain and rod. The Flippac has a double-wall section in the back, which can be drilled easily without breaking through to the outside. I mounted to the bottom of this part to avoid interfering with the hammock hardware. I used 1/8x1/2" steel pop rivets to attach the cleats:
And here is the finished product. I particularly like that I can leave the tailgate and/or window down and still enter through the split in the middle. This also keeps flies and such out.
Here is the parts list I used:
Nylon deck loop:
http://www.amazon.com/gp/product/B00BLDY1IM/
Bungee hooks:
http://www.amazon.com/gp/product/B00CMIG4D0/
Shock cord:
http://www.amazon.com/gp/product/B00IO4M7N2/
Curtains (quantity 2 needed):
http://www.amazon.com/gp/product/B00RAI63IS/
Arclight
First, I looked into curtains, and discovered that 45" tall curtains are a standard size. You may not always see them at Target or Walmart, but they are available. Fortunately, Amazon has a few to choose from. I also ordered a roll of 1/4" bungee cord to hang the curtains from, some bungee cord hook ends, and a bag of heavy-duty nylon boat cleats.
Here is the attached curtain and rod. The Flippac has a double-wall section in the back, which can be drilled easily without breaking through to the outside. I mounted to the bottom of this part to avoid interfering with the hammock hardware. I used 1/8x1/2" steel pop rivets to attach the cleats:
And here is the finished product. I particularly like that I can leave the tailgate and/or window down and still enter through the split in the middle. This also keeps flies and such out.
Here is the parts list I used:
Nylon deck loop:
http://www.amazon.com/gp/product/B00BLDY1IM/
Bungee hooks:
http://www.amazon.com/gp/product/B00CMIG4D0/
Shock cord:
http://www.amazon.com/gp/product/B00IO4M7N2/
Curtains (quantity 2 needed):
http://www.amazon.com/gp/product/B00RAI63IS/
Arclight
DVexile
Adventurer
Love the curtain mod and thanks for the very helpful write up! Great idea using pop rivets into that section of the FlipPac. I shall shamelessly copy!
I discovered on my first weekend with the Flip Pac that it works as an extremely effective bug trap. They wander in the back, fly up into the light and airy tent and never find their way out again. I had an uncountable number of flies banging against the rear screen trying to get back outside after leaving the tailgate open for a few hours. This would seem a very effective way to keep them out and I can already think of a number of slight modifications to suit my particular setup.
I discovered on my first weekend with the Flip Pac that it works as an extremely effective bug trap. They wander in the back, fly up into the light and airy tent and never find their way out again. I had an uncountable number of flies banging against the rear screen trying to get back outside after leaving the tailgate open for a few hours. This would seem a very effective way to keep them out and I can already think of a number of slight modifications to suit my particular setup.
Camelfilter
Explorer
Curtain looks good, thanks for the pics. Mine has something similar & I also ran 2 more along the side windows.
Behind my rear door curtain line, I ran another line for mesh screen. Works great in warm buggy weather keeping the bugs out but great ventilation. When I only use the curtain or the screen the other is rolled up & out of the way.
For driving they're both tucked up under the flip top by the tent so I can see out the rear window.
Behind my rear door curtain line, I ran another line for mesh screen. Works great in warm buggy weather keeping the bugs out but great ventilation. When I only use the curtain or the screen the other is rolled up & out of the way.
For driving they're both tucked up under the flip top by the tent so I can see out the rear window.
Arclight
SAR guy
I haven't needed to haul anything, so no roof rack yet. I'll probably start with another van ladder rack like this one:
http://www.amazon.com/Werner-VR401-W-Steel-Ladder-White/dp/B007A3RFGM/r
Then I'll fabricate some sort of quick-release/handwheel fastener system for taking it on and off. The racks with the tie-down points already built-in work great for hauling things like kayaks, ladders, canoes, etc. I don't think I'll add a safari/basket rack, as this needs to be light enough for me to lift by myself. If I make a deck at all, it will be lightweight and flat.
Arclight
CactusJackSlade
Observer
I'm a FlipPac Newbie, only a few trips so far but love this amazing FlipPac concept.
This is an excellent thread - thanks for all the info, posts photos and links - very helpful.... I've subscribed!
This is an excellent thread - thanks for all the info, posts photos and links - very helpful.... I've subscribed!
ToyotaRoamer86
Adventurer
Came back to your thread for some ideas. I will hopefully be a flip pac owner if all goes well by Saturday!