Isuzu NPR HD Truck Camper Build

VicHanson

Adventurer
I'm not going to take time for photos tonight but just a quick update on the progress. We got the second garage door on tonight (the big one), did the smaller one yesterday. Still need to finish the locks and figure out how to mount the gas struts to hold it open. The large one will open up, all the others open down. I put chains on them today so they can be used as tables. Also got the fiberglass cap/wind deflector screwed in place and the seams sealed, and the last two window installed. One more storage door and one piece of corner trim left to do. I am hoping to be done by Wednesday night, it's going to be close!
 

VicHanson

Adventurer
Thanks John, here's a few current pics. Got the doors all done, rain gutters around the roof, the bathroom still isn't finished but that's about it. Oh, need to put a sealer on the rubber roof. I started loading up the garage today, put the mtn. bike on the front wall with small pulleys, the bike cargo box has to come off to put the bike in, that is also my step to use to load the bike. Just using ratchet tie down straps to secure the bikes for now, would be nice to have a fancy front wheel lock like Doug made but that will have to come later (if ever). Used two 20", 60 lb gas struts for the large garage door, a little tricky to get the right size and mounting location but am happy with the results. The other doors all open down so have chains to hold them at 90 deg. for tables, or they can also open 180 deg.

Will be traveling for most of the next week, so probably won't get the latest build updates posted for awhile. Will report later from Minnesota!

Oh, forgot to mention that the bike got 93 mpg running around town - Nice!

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Ford Prefect

Expedition Leader
WOW

That is certainly not what I was expecting!

It really looks VERY nice! (sorry for under-estimating your plans!)

Congrats on the progress so far! Super build.

Will there be any access to the garage from inside the camper?
 

VicHanson

Adventurer
Got the solar panels yesterday, then drove for hours in a downpour to Coral Springs, FL. Had a bit of a leak in the cabover bed area, I hope it is just around the escape vent cover. Will have to check that out. Got my city driving practice yesterday in Miami, going to take a little getting used to! Need to get the backup camera installed. The truck rides much better with the camper weight on it, although I did hit a few bumps in the road that bounced things pretty good! I can see that I'm going to have to put some mesh or something over the clothes shelves, lots of stuff on the floor when I arrived. It handles good too, I've very happy with it.

FP - Thanks, no offense taken, I had hoped it would look this good, but wasn't sure. Putting on new siding rather than trying to reuse the old was a big key. I had great help and advice from Jim and Dana too, couldn't have done it on my own. No access from the camper to the garage, or from the garage to the cab. The door on the driver's side is almost 4 feet square, the bikes will be loaded and unloaded from that side. The door on the passenger side is smaller, just for convenience if needed.

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VicHanson

Adventurer
Welcome to Expo, Jerry!

I stopped at Walmart in Coral Springs, FL on Saturday evening, got out of the camper and as I was walking around the back to go into the store, I saw a guy walking towards the camper from the other side. He was admiring it and complimented me on how it looked! Felt really good. My first 'stranger in the parking lot' fan!!

I'm in Murfreesboro, TN tonight and all is well, nothing has fallen apart! Have been getting about 14 to 15 mpg, but the price of diesel is outrageous! I paid $3.11 yesterday, finally got some for $2.89 today, but it has been 40 to 50 cents more than regular at most stations! What's going on with that?!?! I'm beginning to think getting a diesel wasn't such a good idea.
 
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West Coast Mags

Adventurer
Just found this thread and read the build. Great Work! I've thought of doing a similar project, reading about your build was inspiring. Thanks for taking the time to share the build up.
 

VicHanson

Adventurer
Metapoint - Thanks and you're welcome.

I got two new tires yesterday for the front end, BF Goodrich Commercial T/A Traction, size 235/85/16E. I was going to get them from Sam's Club, but they said they couldn't mount them on a medium duty truck. So I got them at Discount Tire, also called America's Tire at some locations. They were $159 each, but came to $373.50 total with balancing and tax. I had also just gotten a spare wheel from a truck junk yard in Wisconsin so had them mount the best old tire on that (for $6). Now I need to figure out a mounting for the spare. There is plenty of room on the under the camper on the right side so shouldn't be a big problem.

The tires really look nice and it seems the the steering and handling is better (which might just be my wishful imagination after spending all that money!). I wish I had all 6 new tires but the rear ones are still pretty good so couldn't justify spending another $747.00 now!

Then I went to Northern Tool and got a 8 ton barrel jack, jack stands, a 20" long, 3/4" breaker bar, a 4" extension and a 41 mm socket. I guess I should have gotten the 6 ton jack even though the 8 ton was on sale for a dollar cheaper because it is too tall. I'll have to run the front wheels up on a couple of board to change them.

Of course even though I asked the tire mounter to make sure he didn't over torque the nuts (and he did use a torque wrench), I still can't budge them standing on the breaker bar. Will need to get a long cheater bar and hope it doesn't break the breaker bar.

Unfortunately when I got home, I went to open the camper door and the key wouldn't unlock it. I could unlock the dead bolt but not the latch, have no idea why. After trying for quite awhile I finally broke off the key. I have a spare key but can't find it. In my hurry to pack and leave Florida I must have put it in the camper. I ended up getting a new latch/lock today (and I had just bought that one when I rebuilt the camper) so will try to remove the bad one and replace that tomorrow. Then I need to get started on installing the solar panels.

I also have a slight leak in the roof where the fiberglass cap joins the rubber roof. It is just in front of the emergency escape hatch and there is a pronounced dip in the roof there because there is only about 2" of wood in front of the hatch. I plan on putting a 1"x1" angle iron from side to side on the inside to push it up flat, but so far haven't been able to find any longer than 6', and I need 7 1/2'. I have looked at Lowes, Home Depot, Menards and Ace, nobody has 8 footers. Because of the dip there is a puddle there after a rain and it eventually soaks through the seam, even though I thought I had sealed it well with butyl tape.
 

alaskaboy

Observer
Vic,

Bummer on the roof, sag or no sag.

If you have air service brakes, couldn't you tap into that and carry an impact driver which would be easier to stow, and might possibly be lighter than a 3-4 ft cheater bar?
 

VicHanson

Adventurer
Peter, thanks for the tip on Metalsupermarkets! I will be going right by the Burnsville store when I leave here so will check them out. Yep, with a flat the jack won't go under the axle at all.

Alaskaboy, no air brakes, no air compressor big enough for an impact wrench.

Kerry, did you get that gas powered impact wrench? If not, have you found a solution yet?

I went out this morning to remove the bad door latch from the camper and to put in the new one. Even though the key was broken off, it was just long enough that I could get a hold of it with a vise grip, which was good because the dead bold was locked. I unlocked that and just for fun tried to open the regular latch again. It opened normally! I couldn't believe it but was sure glad I tried it once more before destroying the lock! The only thing I can guess it that the other day when it wouldn't open I sprayed it with WD40. It didn't help any then but maybe it did after sitting for a day and a half! I think the new latch is heavier, it is the same brand but a different number series so maybe it is a better latch, so I might go ahead and replace it anyway.

I got one of the solar panels out today and looked at that to figure out how to mount them. I also tried to figure out where to mount the spare tire. I don't have anything under the bed on the passenger's side so thought about mounting it there. It seems like it should be easy to design a hinged platform with the hinge attached to the frame. With it lowered, the tire could be easily rolled and laid onto the platform and then the whole the whole thing raised up and secured with a chain or a latch of some kind. I was thinking I could make something out of angle iron and just bolt it together but my brother-in-law thought it should be welded together. Anyone have any thoughts about this? The only problem I see is that the tire sticks out beyond the edge of the camper by about 1 ½ or 2 inches. I don't think this is a real problem because the mirrors stick out a number of inches beyond that.

Another option would be to have some kind of a mount that would fit between the cab and the camper, there is just enough room there. I think I saw this on Expo sometime last year, but don't remember for sure. This would be more complicated and probably beyond my ability, and I am sure would require some welding (which I can't do). I might put an extra tire there (not mounted on a wheel). I did get Good Sam Emergency Road Service, it is $79 for the first year on a current special, so decided that was worth it. They will change tires for RVs, as well as mount the tire if needed.

The easiest solution for the spare would be to put it in the bike garage but I don't really want to give up that much space in there, as well as have to remove it every time I put the bike in or take it out. I will probably end up doing that for now as I am going to run out of time before I need to leave for California.

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VicHanson

Adventurer
What's with the big pictures, did Expo change the default? Previously I had tried to post large pics but could only get the small ones when I upload directly to a post. If I copy the URL from another post to a new one, then they come out big. This time I did it the same as always and they came out big, have no idea why.

I forgot to mention that I got some cheap LED lights at Northern Tool the other day as well, a round one about the size of a hockey puck with 24 LEDs and uses 3 AAA batteries for $5, the other is rectangular, about 2x9 inches and has 72 LEDs for $10, which uses 4 AA. Neither are as bright as I had hoped, but especially the big ones (I got two of them). They don't even seem to be twice as bright as the smaller one. One thing that is nice about them is they each have a hook on them and the round one has 1 magnet and the large ones have 3 magnets on the back of them. I got the big ones for my bike garage, so will see if the give enough light for that. If not, I will probably try a 20 or 30W, 120V compact florescent and run it off the inverter.

I just did some more tests in a stairway and now I can see that the large one is much brighter, which the following pictures illustrate quite well.

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The second pic is the small light at 1/4 sec, the third pic is the large one at 1/4 sec.
 

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