Mild 1997 Chevy 2500 build

[mr_ed]

I got the "skeleton" welded up and then glued-and-screwed 1x2's, 2x2's, and 2x4's to it in order to frame in the windows and also provide additional surfaces for the interior and exterior ply to get attached to.

 

[mr_ed]

Getting the second window framed in, and the rear skin on. There will be a large, swing-up door on the back that will allow the ATV to be driven into the back, or sheets of plywood slid in, etc. I want to keep most of the functionality of the pickup without having to unload the camper everytime there's real work to be done.



Finishing the cab-over part.



Rear windows cut into the rear skin. The big swing up door will also contain a small central man-door with a window, which will allow us to enter and exit while camping without having to open the whole back end up and lose our heat. Also got some deadlights cut out in the 45 degree sections between the sides and the roof.



From the rear door, looking forward.



Flipped it over to get the bottom finished off.



I had some hand-me-down paint from a neighbor that I'm using to paint inside areas that will be covered. There will be no bright orange paint showing to the outside world.

 

[mr_ed]

A close up of the heavy duty aluminum foil vapor barrier/radiant poor-man's Reflectix I'm doing. This is kind of a less-than-essential area, but I was testing the idea before I went whole hog installing it in the rest of the camper. I used some industrial spray adhesive to attach the foil to the plywood.



Then the Blueboard foam insulation gets spray adhered to the foil.



Then the outer ply gets put on. Also mocking-up where the spot/flood LED combos will go so I can get the wiring installed prior to the lower cabover skin getting attached.

 

[mr_ed]

One of the reasons I've been lagging on making progress on this camper. Got to take a little jaunt down to Adak Island for a SAR case. Really wish I'd had the opportunity to go poke around the abandoned Navy base...really glad I don't have to live there! Sure was beautiful though!

 

[SDDiver5]

Awesome! Love seeing someone say they want to to build a rig and actually build it! Too many threads on here that are just smoke. Cant wait to see the finished product, nice work!

 

[locrwln]

Looking good.
.
Jack

 

[mr_ed]

Awesome! Love seeing someone say they want to to build a rig and actually build it! Too many threads on here that are just smoke. Cant wait to see the finished product, nice work!

Thanks man! I’m kinda bad about staying on top of my thread here. I try to make steady progress on the actual project, but the thread sort of goes in chunks.

I’ve got a deadline on this, so I’ve definitely gotta finish it. Already bought ferry tickets for June...we’re going to take 2 weeks and do a 2000+ mile road trip all around mainland Alaska and I don’t want to have to tent camp the whole time, so that’ll keep me motivated haha.


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[chilliwak]

I like the progress on your camper there Mr Ed! Looks awesome.:Wow1: Where did you ever get the idea of building a swing up rear door? Your construction looks super strong and rigid. I am looking forward to seeing more pics and detailed info on your build. Cheers, Chilli..

 

[mjmck]

Love seeing the scenery up in AK too. Build looks great so far!

 

[uscg2008]

Hot dang I just missed ya! I got here June of '16. I see you're in SD now...say hi to J Felts for me!

Is that Cape St. Elias in your profile pic? Man I'd love to spend a couple weeks in that bunkhouse they have there, just exploring the island and soaking up the complete lack of anybody there. Except for the ghost monster thing in the keeper's house haha!

Ya it is we were taking some of the ATON guys out there. That places is so cool.

 

[mr_ed]

Here's a little update. Just been plugging away at it little by little. Got everything fiberglassed. I used 8 oz. cloth on the roof and you can jump up and down up there and it barely even flexes. My wife helped me apply some primer tonight, so I'll longboard it tomorrow and begin finishing the rear door.

Gotta get it on the truck so I can get her Montero in for some badly needed preventative maintenance. I'll finish off the interior after it's on the truck.

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[mr_ed]

Primed and flipped. Mocking up the jerry can mount.

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[Kingsize24]

Damn! Very nice. Want to make another one? LOL

 

[mr_ed]

Haha I'm not sure the missus would be super stoked if I started on another. Thanks though!

Just a few more pics. Spent a lot of time with priming and sanding lately. It's not exactly Earthroamer-level finish...more "workboat," but I don't want to spend the rest of my life fairing and sanding just to scratch it up down some brushy trail.

Final coat of paint is on, and the rear door is in the works. I fabbed up a rear ladder to go on the right hand rear. This will make it easy to get from the tailgate up on top since the roof is neck-high when I'm standing on the tailgate.

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[chilliwak]

Ed that looks awesome!:Wow1: