"Jackur" 2003 Ford E350 Diesel 4X4 Build.

graynomad

Photographer, traveller
11 hours of filming and they'll probably use 23 seconds.
I know the feeling, all day filming and a few minutes air time if you're lucky. At least with our last show we had 1/3rd of the episode which was nice.

Re the gas struts, you can have them re-gassed to whatever you like, so if you get it wrong just call your local gas-strut-regasser-guy and have them changed (well you can do this in Oz, I assume the same in the US). Also when building it's useful to get a couple with just a few PSI in them so you can play around with locations. When done gas them up to whatever you need.

Now I have to go back and re-read the part where you describe the panel manufacturing, maybe I don't really need $10,000 of composite panels after all :)
 

Haf-E

Expedition Leader
Very nicely done - I haven't been able to find the section on making the sandwich / composite panels up - can you give more detail on it or point me to the message where it's explained?

Never have seen a "regasser" for the struts here in the US - that would be interesting to hear more about.
 

graynomad

Photographer, traveller
Re gassing is standard procedure over here, the process is used mostly for people with old vans and hatchbacks whose struts no longer hold up the door. As you guys would have the same problem I would assume you have the same solution, but maybe the US has a law about high-pressure cylinders being used in a van on the side of the road :)

The struts have a one-way valve arrangement, to up gas all you do is put them in a pressure chamber and pressurise to the required level. To down gas you can poke a thin metal sleeve between the rod and the casing to let gas out.

All this is typically done on site by guys in vans.
 

Abitibi

Explorer
That's bizarre. We have them north of your border here in BC so hard to imagine you guys don't.


Sent from my iPorn using TapaChat
 

dentedvw

Wire twister
There is lots of them. Elko, Fox, etc. They are expensive to buy the first time, but many of them can be rebuilt. I bought some Fox shocks, used, and they needed only minor cleaning. They are nitrogen charged, no remote reservoir. A bit expensive, but what the hey. I was tired of replacing cheap shocks. Off road shops can charge them, recommend a pressure, etc. Especially where you live, I imagine it shouldn't be hard to find some used one, or new. Should be lots of shops too, these places will often specialize in pre-runners, and desert buggies.
 

Rbertalotto

Explorer
Great build...Amazing design work. Love the ladder..

Have you ever worked with "Wacky Wood" for all those curved sections. Wacky Wood is plywood where all the plys go the same direction. It can be wrapped around a 6" cylinder in the 1/4" thickness size.

But I have one comment.........I love 99.99% of your work.....But the piano hinges on the outside of the cabinet is...um...not in keeping with the whole build. And if installed properly on the inside edge of the door, they make the door panel much more rigid.
 

shachagra

Adventurer
She's back

IMG_3821.jpg
The van is back in my driveway after two years.
Unfortunately Lost…Again, the owner has past away, a victim of a biased, relentless judicial process that stripped him of fatherhood for no reason at all other than the imagined fear of a vindictive almost ex-wife and her bulldog, man-hating lawyer. Tom took his own life rather than face life as a felon after 33 years of honorable service and numerous deployments to Iraq and Afghanistan. Who would think that trying to see your boys after 13 months time and just a few miles distance could lead to an FBI SWAT team raid on your house (lived on the NH Vermont border, crossed the state line), and an eventual sentence of 14 months in a federal prison. Rising from an enlisted man to a Navy Captain is meaningless if the local police wanna-be's think that your being a veteran Explosive Ordnanceman with a whiney wife equates to the uni-bomber. The restraining order was issued based on his "special skills" and not a single incident of abuse.

Enough on that, but I just spent a year fighting in court to keep the ***** from getting the van. Tom left it to me in his final E-mail and a signed (but not with two witnesses) statement.

I'm waiting for the SWAT team to show up at my house any minute! That would be funny if not so true and scary.

Back to the van. It is great, 2003 was the last year for the 7.3L power stroke, wouldn't meet emission specs so away with a million mile motor, Quigley 4X4, and Tom had every pice that could be brought back to new replaced. It was a labor of love for Tom, new air-ride seats, compressor system, stereo, he had it lifted, added Toyo Tires and powder coated wheels. The top, I am happy to say works really well and she opens up and closes in about 90 seconds. I know Tom got great enjoyment out of it, used it on a few off-road motorcycle trips, and for that I am very happy.

There are still a few upgrade plans now that we know the concept works.

-New top- the cap- just the very top- will be rebuilt. There are some stressors from the gas struts that have been beefed up, but need to be addressed at the structure. The new top will be made out of all marine grade materials and much greater detail. First time through we just needed to see if it would work.

-10,000lbs Warn Winch. I bought it for my larger RV but think it will go well on Jakur.

- Webasco diesel stovetop. I pulled it out of my larger RV because Shachagra produces so much electricity that an induction stovetop replaced it. It will go well in Jakur. I am going to remove the LP heater and LP tank, go all diesel.

- Rearrange the interior just a bit and finish the trim and window coverings.

That's a start, I'm trying to figure out a way to carry a zodiac on the back without a trailer (I'm just not into trail bikes)

I'll bring the upgraded Jakur to the Expo next year- Tom tried to do it two years ago. better late than never. RIP Tom, I'll finish the project and my family and I will think of you always.

IMG_3818.jpg
 
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shachagra

Adventurer
Great build...Amazing design work. Love the ladder..

Have you ever worked with "Wacky Wood" for all those curved sections. Wacky Wood is plywood where all the plys go the same direction. It can be wrapped around a 6" cylinder in the 1/4" thickness size.

But I have one comment.........I love 99.99% of your work.....But the piano hinges on the outside of the cabinet is...um...not in keeping with the whole build. And if installed properly on the inside edge of the door, they make the door panel much more rigid.

I have not tried wacky-wood. It sounds interesting. Its those compound curves that are the tricky ones. The piano hinges are on the face for two reasons (3 if you add that I like the way it looks..) The rigidity of the doors comes from a lip that the door fits into, gets in the way of a continuous hinge- which I love for durability. Second, with plywood, screws don't grip well into the edges but very well into the face, cross ply. With the inner lip there is 1" of plywood for the screws to grip into. Very sturdy. Thanks for the critique though, there needs to be more of that, it is nice to be friendly but a useful critique can be used.
 

1der

Observer
What a day to stumble upon this thread. Condolences, admiration, and amazement. The journey continues.....
 

ujoint

Supporting Sponsor
Wow, sorry to hear all of this.

Had the pleasure of meeting Tom when he swung by the shop for some work. Great guy, will be missed. Glad the van is in your hands now.
 

shachagra

Adventurer
Wow, sorry to hear all of this.

Had the pleasure of meeting Tom when he swung by the shop for some work. Great guy, will be missed. Glad the van is in your hands now.

Small world- you must have done the lift she's sporting since I last saw her. it looks great. During the court proceedings his wife mentioned that he had spent money on a "U-joint"
That must have been you.
 

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