Isuzu NPR HD Truck Camper Build
- Thread starter VicHanson
- Start date
VicHanson
Adventurer
Thanks, Kerry. Yes, it is a very nice workspace. Probably not fair to call it a driveway build because on one the side of the driveway are four "carports" with 13' ceilings (I'm using two of them), and right behind that is a fully equipped workshop with practically every tool I know how to use, and many more that I have never seen before. Almost all of them are professional wood shop or construction tools, no 'home' stuff!
Today we got the bike garage roughed in, still haven't finalized the doors, but are considering doors on both sides now, with one folding down to make an outside cooking/eating area, the other side for bike entry/exit.
The passenger side storage is almost finished, just need to put insulation on the outside panel and screw it on. The propane tanks have been moved to the other side (to open up for the side door), the tank compartment is in place and one of the storage areas is finished, except for the door. We got the hinges and door trim, and found out that Dana, (he has the aluminum shop) has some locking latches that someone ordered and then didn't want them, so he said I could have them. I am also planning on getting sheets of aluminum from him for siding, it is a bit expensive but will be easier and look better than trying to reuse the old siding. Yeah, the camper is WAY over budget, as well as way over the time schedule. Oh well, hopefully retirement will last a long time!
Vic
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VicHanson
Adventurer
Making some slow progress, have been spending lots of time thinking and planning so hopefully will minimize the mistakes. Of course, there are no plans or blueprints to follow, so everything is worked out on the fly! Right now I'm trying to figure out how to do the garage and storage doors, so they seal well and don't leak. I'm also trying to figure out how best to fit the battery box and 40 gallon water tank in the bike garage. Sure would be easier if I had the motorcycle, but haven't found one yet.
I finished insulating on the bottom today, and got most of the rest done, except for areas that need wiring and plumbing work. Hopefully will start putting the outer plywood on tomorrow, and planning the layout of the siding. I have 6 pieces of 4x8 and 2 of 4x10 aluminum sheeting, about $320 worth. I'm a bit nervous about cutting into that!
Still need to get the LP gas hooked up to the stove and water heater and see if they work. I was a bit too anxious to get started on it at the beginning and didn't think of checking them out before I tore things apart. After patching the black water holding tank, I noticed that the attached shower pan had another hole in the side that I hadn't seen before. It is very brittle and in bad shape so I decided to just replace the whole thing, got one ordered today. Unfortunately we broke the outlet pipe off the gray water tank when we were removing the beams after putting it on the truck. I haven't been able to find a suitable one at a decent price, so might try to fix that one. At least it is below the camper so if it leaks I can see it and do something about it, and it won't do any damage to the floor, like the black water tank which is inside.
Insulation, and 2x4 spacers on the bottom to raise the camper up, roofing material on the flatbed.
The bike garage, supports for the clothing shelves.
Shelves, and side views showing the storage areas.
I finished insulating on the bottom today, and got most of the rest done, except for areas that need wiring and plumbing work. Hopefully will start putting the outer plywood on tomorrow, and planning the layout of the siding. I have 6 pieces of 4x8 and 2 of 4x10 aluminum sheeting, about $320 worth. I'm a bit nervous about cutting into that!
Still need to get the LP gas hooked up to the stove and water heater and see if they work. I was a bit too anxious to get started on it at the beginning and didn't think of checking them out before I tore things apart. After patching the black water holding tank, I noticed that the attached shower pan had another hole in the side that I hadn't seen before. It is very brittle and in bad shape so I decided to just replace the whole thing, got one ordered today. Unfortunately we broke the outlet pipe off the gray water tank when we were removing the beams after putting it on the truck. I haven't been able to find a suitable one at a decent price, so might try to fix that one. At least it is below the camper so if it leaks I can see it and do something about it, and it won't do any damage to the floor, like the black water tank which is inside.
Insulation, and 2x4 spacers on the bottom to raise the camper up, roofing material on the flatbed.
The bike garage, supports for the clothing shelves.
Shelves, and side views showing the storage areas.
chris_the_wrench
Fixer & Builder of Things
VicHanson
Adventurer
Hi Chris,
The aluminum is .040. I was hoping for off white but all he had was white. It will just be for the sides, the top has a rubber roof. It will go on over 5mm Lauan plywood.
Vic
john101477
Photographer in the Wild
turning out pretty good Vic. i almost have my wife talked into it. :victory:
VicHanson
Adventurer
Thanks, John. Make sure you get a camper in good shape it you go that route. I still think it might have been easier and quicker to build one from scratch than what I have been doing. Oh well, I think I can see the light at the end of the tunnel, although just got a notice today that the shower pan/holding tank I ordered yesterday is on backorder - they didn't say for how long. I got the latches today, along with a drip gutter for the top of the doors, so can start on them next week.
I would say this is sound advice. I went by Friday to see Vic's progress and I have to agree it probably would have been easier to start from scratch than what he is doing!
On the flip side he is doing a great job and seems to be taking it in stride.
Keep it up Vic, you'll be on the road before you know it! :sombrero:
VicHanson
Adventurer
I finally made some visual progress today, I got the Lauan plywood on the right side of the camper! It was a little tricky doing it alone, but managed to do it. First I tried to determine the best usage of the plywood, with the most structual tie in as well as not wasting wood, then made a drawing of the area, and measured it with all the cutouts. Then I tacked the plywood up in place to check the fit and make sure the cutouts were marked right, then took it down and cut them out. Next a final test fitting, tacked it in place again and marked where the wooden framework was for attaching, took it down and applied heavy duty Liquid Nails liberally, tacked it up again and then stapled it using a pneumatic stapler. I had originally planed on screwing it on but this was much easier and faster. It took most of the day because I remeasured everything over and over, did lots of thinking and took a couple of breaks.
I think it was Wednesday I received the 40 gal. water tank and got that mounted. After much thought and discussion, I finally decided that the only way to get both that and the battery box, along with the motorcycle in the garage was to put the water tank on the bottom and the battery box on top. Both will weigh over 300 pounds loaded and the batteries need to be accessable from the top of the box. I also had to build a 4 inch base under the water tank to bring it up to the same level as the original 16 gallon in the camper. They will equalize by gravity feed for both filling and pumping (using the original pump).
Yesterday I built the battery box support, which fits over the water tank, out of 2x4s and 1 1/2" angle iron. It needed to be strong, stable and solidly attached, yet removable in case of problems with the water tank. I also made a vent in the box using a 1 1/2" PVC pipe coupler.
Last week while looking at the maze of wires at the back of the camper, I realized that I didn't need lots of them because they all went to the front of the camper to be plugged into the truck. I will just hook the signals, brake lights and clearance lights directly into the truck wiring at the back of the truck. I was also able to eliminate the 12v wiring for the fridge.
I decided to reuse the camper tail/brake light fixtures even though they weren't really needed (the truck lights are visible below the camper). They were designed to mount into a hole cut into the shell but I didn't want to do that in the new aluminum skin, so I made surface mounting frames out of 2x4s. The only holes needed will be for 2 screws and 1 hole for the wires. They are all painted and ready to install now.
Hopefully tomorrow I can cut and lay the linoleum and put the closet in place. I received an email saying that the back ordered holding tank shipped on Wednesday, so hopefully will have that by Monday and we can install that and finish the plumbing.
Tail lights and mounting frames, since painted white
Reinforcing straps at the front of the bike garage, and the 40 gallon water tank
Supports and battery box for 6 Trojan T-105 6v deep cells, vent hole
First piece of plywood, plywood on one side finished!
I think it was Wednesday I received the 40 gal. water tank and got that mounted. After much thought and discussion, I finally decided that the only way to get both that and the battery box, along with the motorcycle in the garage was to put the water tank on the bottom and the battery box on top. Both will weigh over 300 pounds loaded and the batteries need to be accessable from the top of the box. I also had to build a 4 inch base under the water tank to bring it up to the same level as the original 16 gallon in the camper. They will equalize by gravity feed for both filling and pumping (using the original pump).
Yesterday I built the battery box support, which fits over the water tank, out of 2x4s and 1 1/2" angle iron. It needed to be strong, stable and solidly attached, yet removable in case of problems with the water tank. I also made a vent in the box using a 1 1/2" PVC pipe coupler.
Last week while looking at the maze of wires at the back of the camper, I realized that I didn't need lots of them because they all went to the front of the camper to be plugged into the truck. I will just hook the signals, brake lights and clearance lights directly into the truck wiring at the back of the truck. I was also able to eliminate the 12v wiring for the fridge.
I decided to reuse the camper tail/brake light fixtures even though they weren't really needed (the truck lights are visible below the camper). They were designed to mount into a hole cut into the shell but I didn't want to do that in the new aluminum skin, so I made surface mounting frames out of 2x4s. The only holes needed will be for 2 screws and 1 hole for the wires. They are all painted and ready to install now.
Hopefully tomorrow I can cut and lay the linoleum and put the closet in place. I received an email saying that the back ordered holding tank shipped on Wednesday, so hopefully will have that by Monday and we can install that and finish the plumbing.
Tail lights and mounting frames, since painted white
Reinforcing straps at the front of the bike garage, and the 40 gallon water tank
Supports and battery box for 6 Trojan T-105 6v deep cells, vent hole
First piece of plywood, plywood on one side finished!
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From what I gathered from Vic's website, his boss is non-union but generous with time off.:sombrero:
VicHanson
Adventurer
The pay isn't very good the the hours are great! 14 days until I turn 62, and can get my lifetime National Parks pass. Social Security doesn't start until July sometime. I did some shopping yesterday after church, then took the rest of the day off and went hiking - there should be some fun in retirement!I got the linoleum measured, cut and laid today, it came out almost perfect, I was really pleased. I ended up making a pattern out of newspaper on the floor of the camper, and then used that to cut out the linoleum. UPS brought the holding tank/shower pan so can install that soon. I also put in the clothing shelves, and closed up the old rear door area. It's starting to look good.
I got a surprise call today from a pastor here in Florida that I worked with some in Peru. They have asked me to consider taking a group to Peru for a week! It isn't for sure yet but if it happens, it will be in a couple of weeks.
I also have a new deadline date that I need to have the camper done for. I was contacted by a family from Spain that were looking for a guide for about 10 days of hiking. We have decided on the Tahoe Rim Trail, I need to pick them up in San Francisco on August 3rd! After the hiking we will make a trip down to Yosemite. A little extra income will be nice, especially to help pay for the high cost of fuel.
VicHanson
Adventurer
Seems like I haven't accomplished much lately, have been waiting for a few things, like plumbing, that are holding up everything else. I have been finishing up a few odds and ends, like finally got the fiberglass bed cap all cleaned up and ready to paint, checked out the oven, that works fine but the gas fitting has a small leak so need to redo that. The plumbing is getting there, still need to hook up the new tank to the old one so that they will fill and pump at the same time. Unfortunately I didn't take pictures of the plumbing before starting and now I don't remember how the 'city water' connection was hooked up to the system. Can't figure out what keeps the tank from overflowing when it is hooked up to a water hose in a camp ground.
My advice to anyone doing a similar rebuild is to take extensive notes and photos before you start on anything. I thought I had done enough but I didn't. I did end up rewiring most of the camper because of removing the refrigerator and air conditioner, as well as the old DC input was all up front. Mine will be coming from the back of the truck, so was able to eliminate a lot of wires. I'm also hooking up the turn signal/brake lights directly to the truck ones so that wiring is a lot simpler.
Today I finally got new vent covers ordered from PPL in Texas, as well as a few other things. Their prices are fairly decent and I am still not able to drive my truck. RVSurplus in Indiana was cheaper on the parts, but their shipping costs were outrageous! $60 for the parts and $85 for shipping. I ordered more stuff from PPL and the shipping was $19.00! Northtrail RV here in Fort Myers (and I think Fort Lauderdale) has a huge catalog with lots of stuff in it too. I will probably end up getting some things from them.
I ended up fixing the old gray water tank with 3M 5200 adhesive, hopefully that will work OK. If it does leak later, it can be reached from below the camper, behind the truck frame, unlike the black tank which is inside the bathroom, under the toilet.
Most of the Lauan plywood is on, except where access is needed for plumbing work, will probably start putting the aluminum siding on the door side in the next day to two. The interior is mostly done, except for the bathroom.
Still having registration problems. I had my sister in Minnesota try to register it for me as an RV but they said I needed to fill out an affidavit of reconstruction, with details of work done, receipts for all 'major' parts, bills of sale, notarized, photos, etc. I got that sent to my sister yesterday, hopefully it will be sufficient.
And I leave for Peru in a week!
New and old holding tank/shower pan. New flooring
New door where the old fridge was. New clothes shelves, and new fridge where old door was.
Getting the plywood on the driver's side
My advice to anyone doing a similar rebuild is to take extensive notes and photos before you start on anything. I thought I had done enough but I didn't. I did end up rewiring most of the camper because of removing the refrigerator and air conditioner, as well as the old DC input was all up front. Mine will be coming from the back of the truck, so was able to eliminate a lot of wires. I'm also hooking up the turn signal/brake lights directly to the truck ones so that wiring is a lot simpler.
Today I finally got new vent covers ordered from PPL in Texas, as well as a few other things. Their prices are fairly decent and I am still not able to drive my truck. RVSurplus in Indiana was cheaper on the parts, but their shipping costs were outrageous! $60 for the parts and $85 for shipping. I ordered more stuff from PPL and the shipping was $19.00! Northtrail RV here in Fort Myers (and I think Fort Lauderdale) has a huge catalog with lots of stuff in it too. I will probably end up getting some things from them.
I ended up fixing the old gray water tank with 3M 5200 adhesive, hopefully that will work OK. If it does leak later, it can be reached from below the camper, behind the truck frame, unlike the black tank which is inside the bathroom, under the toilet.
Most of the Lauan plywood is on, except where access is needed for plumbing work, will probably start putting the aluminum siding on the door side in the next day to two. The interior is mostly done, except for the bathroom.
Still having registration problems. I had my sister in Minnesota try to register it for me as an RV but they said I needed to fill out an affidavit of reconstruction, with details of work done, receipts for all 'major' parts, bills of sale, notarized, photos, etc. I got that sent to my sister yesterday, hopefully it will be sufficient.
And I leave for Peru in a week!
New and old holding tank/shower pan. New flooring
New door where the old fridge was. New clothes shelves, and new fridge where old door was.
Getting the plywood on the driver's side
whatcharterboat
Supporting Sponsor, Overland Certified OC0018
Hi Vic, man you sound like Job. I just saw this old post about the ABS cement and then the 3M bit......
I'm pretty sure you could make your own ABS cement by collecting ABS powder (just hold a small piece of ABS on an angle grider and remember to stop before you reach your fingers) and then stir it into some Methylethylketone (M.E.K.) until it's all dissolved and you end up with the correct consistency. Not MEKP either, just MEK.
I seem to remember fixing old ABS sailboards that way in another life......
BTW, :birthday.sml:
Kind regards
John.
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VicHanson
Adventurer
My 'RV' is registered!!
I got great news from my sister in Minnesota today, she was finally able to register my camper there as an RV. Yeah! I guess they liked all the pictures I sent them. I do have to take it in for a visual inspection when I get to Minnesota. Now as soon as I get the new title I can contact Progressive Insurance and try to get my insurance changed from a commerical vehicle to an RV as well.
Thanks for the birthday wishes, John. Just turned 62 so now I'm eligible for Social Security and the $10 lifetime National Parks pass!!
I got great news from my sister in Minnesota today, she was finally able to register my camper there as an RV. Yeah! I guess they liked all the pictures I sent them. I do have to take it in for a visual inspection when I get to Minnesota. Now as soon as I get the new title I can contact Progressive Insurance and try to get my insurance changed from a commerical vehicle to an RV as well.
Thanks for the birthday wishes, John. Just turned 62 so now I'm eligible for Social Security and the $10 lifetime National Parks pass!!