FWC Flatbed Hawk, Ultimate Build

[pawleyk]

Hey guys,

I haven't posted on here in a long, long time. Facebook got me for a while, and so did traveling around, then a surprise small business.. but I'm back!

Since it's been a while, I'll do a quick intro: I had a 2016 Four Wheel Camper Grandby on the back of a 2005 Silverado HD. In 2016 I left Oregon and headed South. Through Mexico, Central, and South America I spent about four years on the road, basically full time. Along the way I made lots of modifications and alterations to my Grandby and got to know the ins and outs of Four Wheel Campers very, very well.

Once I was back in the states, I was kicking around, looking for something to do and accidentally fell into wiring vans and campers in the Reno NV area. We now have a shop here, specializing in lithium and solar power installations, and do A LOT of FWC power installations. We average about two Four Wheel Campers each week, along with all the other vans, campers, and occasional expedition truck that roll through.

We also do quite a few diesel heaters, fridges, etc.

I LOVED my Grandby, but I always was left wanting for more "bulky" gear storage. I'd build a custom utility bed for the old truck, but really like the idea of a long bed truck, with a shortbed, flatbed model camper, and a large tunnel box/gear garage to carry things like bikes, climbing pads, skis, etc.

With that in mind.. I found a 2017 GMC Sierra HD, RCLB and ordered up a brand new FWC Flatbed Hawk. I planned to do most of the systems installation here in our shop, so checked only two options: The thermal pack, and the little cushion over the water tank cabinet. I was told it's the second cheapest flatbed camper ever ordered.

A few pics of the old rig, in beautiful places:

 

[pawleyk]

As much as I loved the Grandby, there were a few things I wanted to improve/address or simply upgrade over the factory offerings.

First was, of course, the storage issue for bulky items. The shortbed camper on the longbed truck got me a solution for that, which I'll write more about on the build thread for the truck (that I haven't started yet).

The second is that the current offering for a furnace from FWC has been much less than reliable. I never had an issue in my 16, but most newer camper seem to struggle with this constantly. There are lots of heating options out there, and the diesel heaters have been very popular lately.

However, my truck is a gas as I find modern diesels too heavy, too expensive, and too complex for long term, remote travel. So, a gas fired heater it is.

I've also found propane to be difficult to source sometimes. Never impossible, but certainly more difficult than simple unleaded. Since I've already decided to replace the cabin heater with a gasoline fired option, I'm that much closer to eliminating propane altogether.

We'd installed a couple diesel fired hydronic systems from both Webasto and Ellwell, but Ellwell are located in Washington state and offer a system that runs on gasoline, alongside their diesel option.

Timberline – Elwell Corporation

elwellcorp.com

For those of you unfamiliar with hydronic systems, they use a fuel fired coolant heater to heat a glycol loop, which then circulates through a water/water heat exchanger to provide instant hot water, and through a water/air heat exchanger to provide warm air for cabin heating.

In our experience, they're fast, efficient, and let you use the same fuel you're using to power your vehicle.

We installed the bulk of the system below the sink, where the factory hot water heater would be installed (this camper just had a big empty space there, as I didn't order hot water as an option).

The Timberline system by Ellwell comes with a nice, all-in-one touch screen controller and allows you to control the coolant heater, water heat, and cabin heat all in one place. We installed it next to the Simarine battery monitor above the refrigerator.

We ran the exhaust and intakes out the wall next to the heating system using these bulkhead fittings:

Photos of the camper, brand new and unmolested just delivered. Also the exhaust port on the outside wall, installation in progress of the hydronic system, and a completed hydronic system in a van, but in a much easier to see place.

 

[pawleyk]

Here's a closer shot of the timberline control panel (next to the Simarine monitor we'll go over in a bit)..


And a picture of the Scepter boat tank I found that fits into the old propane cabinet perfectly:


Link is here: We're using the 3.2G

In this interior shot, you can see the grate we installed for the cabin heat exchanger/fan assembly. It's the nickle plated one in the lower left corner:

 

[pawleyk]

With the hot water and heat taken care of, the only propane appliance left is the cooktop. As I said up top, the specialty of my shop is lithium power systems and solar. We've done a few vans etc. with induction cooking and it's always intrigued me. The actual experience of cooking on induction is really great, fast and efficient.

I picked the stove I thought would fit that had the best reviews on Amazon, and pulled out the factory gas top. The stove wasn't quite the right size to just fill the hole, or make a new one, so I had to make a stainless adapter plate to make it fit without gaps.

 

[Overdrive]

Very interesting build. Love it.

How much solar/battery capacity do you figure you'll need with everything--especially that induction stove top?

 

[pawleyk]

Very interesting build. Love it.

How much solar/battery capacity do you figure you'll need with everything--especially that induction stove top?

I'll do a more comprehensive post on the power system, but have been really pressed for time lately. I'm using 300ah of battleborn lithium, 660w of Sunpower solar on the roof, 30amp victron DCDC charger from the truck. The stove pulls lots of power, but it's really efficient. Draw relies heavily on the quality of the induction cookware and the size of the pot being used. My stainless Moka Pot pulls 30dc amps to make coffee, for about 3 minutes, with the stove on high. A larger pan pulls more. Soup pan, about 60amps, and a large frying pan 130dc amps or so. I find things cook quicker, and more evenly than with other cooktop methods.

Also, with all the solar, we can cook a simple hot lunch and the sun will have recharged the batteries by the time we're done eating.

 

[chinooksupertruck]

Nice build! I’m currently shopping for a flatbed camper but I keep hearing people complain about the FWC and how they are antiquated etc. I take it you enjoy them?

 

[Pacific Northwest yetti]

This was his dream FWC build, and its a nice camper. Works well.

Kp will chime in here shortly, this one is for sale, or will be listed in the next few weeks.

The only reason he is selling is as he is a dealer for OEV now, and has a flatbed HBE that will be here probaly at the end of the month.

 

[Mr.141]

Nice build! I’m currently shopping for a flatbed camper but I keep hearing people complain about the FWC and how they are antiquated etc. I take it you enjoy them?

I had a 2021 Hawk and loved it! Coming from toy hauler trailer world the 4WC had everything we needed. What do you mean ppl say they are antiquated?

I really really really regret selling it.

 

[kmacafee]

check out the Bundutec Odyssey