GMC W4500 (Another Isuzu NPR build)

[miwhexp]

Not sure if I previously posted in the right place...moved my post here...seems more like the place to put in a build thread.


Greetings all -

I've been a lurker for some time now, both here and on ADVRider. I've decided to take the plunge after reading all the great posts and experiences others have had building their "Expedition" camper. After spending a lot of time camping in my trusty Maggiolina on my Excursion and Jeep Wrangler,

and even pulling a Travel Trailer, I've decided it's time to build what for me will be the best camper for my specific needs. For the most part the "camper" will be staying onroad with occasional jaunts onto "groomed" or at least reasonable dirt/gravel roads. When the going gets tough, that's what the Jeep or my KTM will be for. Reading all the great discussions on frame design and pivot points etc., I thought it would be simpler to go with a rig that will allow me to stick with more of a rigid frame and not have to worry too much about frame/camper flex. I also wanted to boost up my gas mileage a bit over pulling a trailer with my Excursion. With that target in mind, I've procured a 2005 GMC W4500 or Isuzu NPR. It's got a 5.2L 4cyl engine with approx. 195hp...enough to cruise nicely on the highway, but still get me into the 12 to 16mpg range on fuel economy (a good bit over the 10mpg I get pulling a TT or should I say parachute behind my truck).

I have begun the process of looking for/or building some sort of "box" and having a bit of trouble making up my mind on which way to go. I've looked at potentially having something built similar to the UNICELL mods done for another poster on their FUSO...seemed a bit steep at $20,000 or so, when you can get 75 percent of the way there with one of UNICELL's standard boxes for $6000.
I've looked at Doug Hackney and Vic Hanson's posts on using a pickup camper (I like the bike garages and the ability to take off the camper), but I have the need to sleep 4 people and I'm not sure a pickup camper alternative is optimized for 4. Another alternative might be the flatbed campers offered up by Northstar campers...not bad. Lastly, I think it might be neat to just build from scratch or mod out a standard cargo box of some sort. I have looked at Rinocore, and Nidacore and other premade panel options, but they are a bit expensive (although still acceptable), I'm just not sure how you might get the rounded edges you can get with a fiberglass/FRP/aluminum/wood solution. I do like the idea of building on a standard steel or aluminum flatbed frame...and possibly being able to detach the camper from the flatbed either at a camping site or to use the truck for other purposes. I've looked at lot of German sites and even talked with some German and Swiss Camper DIYers on a recent trip to Europe...I think possibly copying some of their ideas would also be useful. I guess without rambling on, I was hoping I might get a bit of feedback from other members as to why they went the way they did, and what leanings they might take if they were in my shoes. Thanks for the help.

 

[miwhexp]

GMC W4500 continued

Well, the build continues…now that the holidays are over, we are making headway slowly….slowly. Looked at a lot of truck beds out there and decided to go with aluminum over steel. The main consideration was weight of course. We also wanted to make sure we got a bed with headboard (or headache rack as it is called by some), in case we want to go for a removable “house”. We don’t want the house coming forward onto the cab in case of an accident. We looked at either having the bed custom made or having it done by a company that makes beds for a living. After looking for quite some time we found we realy liked the beds being built by Bullhead Products of Kodak Tennessee. It was great working with them, first class…good product, good price. They were even very helpful in getting the bed shipped out here to the west coast for a decent price. Man, shipping nowadays is a killer…we were lucky to find a truck heading west that needed another small load to round out an already big load going up to the Seattle area.

 

[97discosd]

Very nice!

 

[bajadulce]

That is a really really nice bed! Funny how you refer to the delivery of it as "small load" I love those NPR trucks and you see them everywhere here in the U.S. Been keeping an eye out for a wrecked one w/ a 3.9L 4cyl diesel to put into an old 1966 F250, but don't think I've put enough effort into the chase.

Portable camper designs sure are practical and you'll have a great flatbed truck to use when not camping rather than a parked rig with a permanently attached box. I agree, you'll get the most out of building your own box from scratch. Some of the high tech panels such as nidacore do seem a bit expensive, but they sure look to save a lot of work and are probably worth it for a base rig as nice as yours.

I've been entertaining the idea of building a shell with ABS pipe frame and frp sandwiched between rigid insulation just to do it. My project would be more of a small shell for a pickup not something as large as yours. I have always tended to scrap around for everyday materials for whatever project I was working on. Guess I just get a big kick doing things on the super cheap. This route tho doesn't always save you tho in the end as it can be very labor intensive. Sometimes just spending a little more money and buying the "right" materials saves a ton of time rather than making something else work. Maybe you can find other places of the build to save and just spend the extra coin on securing the wall materials.

Lots to discuss and to explore on the box planning process. You have quite a little journey ahead! Are you anxious?
Steve

Also, I'm gathering general information on flatbeds, and am curious what the distance from wheels to bed is on your particular setup?

 

[miwhexp]

Still working on it just slow

Thanks for the comments...sorry did not post sooner, been sidetracked lately. Answering your questions Steve...yep, bed was a small load...here is what the trailer looked like on the Big Rig that brought it here. My bed was the "light" load.

As for the distance from the bed to top of wheels in the back it's about 6.5 to 7 inches. Plenty of room, been going up and down our bumpy dirt road and it's never even close. Anxious, a bit, about making it right or at least capable. I'm sure it won't be the ultimate build, but I hope it will do what I need it to. Look forward to seeing more about your project.
Current status...added BF Goodrich Commercial TA tractions on the dualies, and Commercial TA all-seasons on the front. Climbs our dirt road without problems...not truly "offroad" challenging, but covers most roads we would ever be traveling. Next step is getting the middle section of the aluminum bed covered with Line-X...anyone on forum done that? Checked around, and it looks like it should provide a bit more "traction" and protection for the main surface the "house" will be riding on.
I think I'm going to go with a mostly aluminum with a bit of wood frame for the house, partially welded and and some parts "bolted". Step by step...just time and money.

 

[miwhexp]

Still working

Well, haven't made a lot of headway, but did manage to build some rails for the bed, so I can carry the parts to build the house with. I also found out that both Rhino-Liner and Line-X will not stick to aluminum without sandblasting first...hmmm...don't think I want to do that to my nice new bed. I think instead I will Line-X the bottom of the frame that the "house" will use...not as traumatic I also finally got a weight on the truck w/bed...6280lbs give or take. That puts the bed in at around 1000lbs or so. Not too bad. Here is the latest pic.