Recalled to life: my 80 (re)build thread

[Ranchero]

I've had my 80 (1996) 2.5 years now and haven't had much to contribute for a build thread. I bought the truck from my friend John who did all the good, fun, and expensive stuff and sold it to me. When I got it it look like it had been hit with a Slee truck - a full complement of armor- bumpers, sliders, roof rack, OME lift, ARBs lockers, etc. It was built for wheeling and John did a lot of it. I, on the other hand, like to travel across landscapes (as dirty as possible) for several days to weeks at a time and my needs are just a bit different.

Since I've had it, I've done PM, spent boatloads on gas, added a second battery and have installed 12V, a fuse block and some 12v sockets in the rear. That's it.

My goals for this build:

• #1 Have fun
  and the rest in no particular order
• Increase fuel mileage (or at least don't decrease it much)
• Lose some weight if possible, especially rotating mass
• Be able to sleep in/on and near vehicle
• Carry three (and sometimes four) people comfortably
• Incorporate fridge and stove
• Have cold and maybe hot water on board
• Onboard air
• Incorporate 3g/4g communications for work
• Move HighLift into pass compartment
• Have the ability to move gear between the 80 and my Syncro.

My crude plan:
I've bookmarked a bunch of the cool builds you guys have done - read through those again in the coming weeks.
Build a platform system out of 80/20 and plywood using Wolf boxes as storage.
Replace steel wheels and 305/70/16 MTRs with stock aluminum wheels and 285/75/16s or maybe 255/85/16s (ST Maxx likely)
Replace ARB roof rack with FrontRunner full length rack
Fridge with slider
Convince Mrs. Ranchero that a rooftop tent may not be the best idea, but that's not likely to happen.

I already have a perfectly serviceable platform built out of 1/4 aluminum sheet and angle iron that mounts using the factory third row seat quick-release mounts. The platform comes out very easily. It also seemed really heavy so I hatched a plan to replace it with aluminum frame and plywood. Wishful thinking and a twitchy index finger while surfing ebay lead to the purchase of some 80/20 stock before researching potential weight saving carefully. It looks like the 80/20 won't save much, if any weight, but I'm going to reinvent the wheel in any case. Gotta do something to the truck to put my thumbprint on it.

Obligatory Moab pic:


What it looks like now...

And with some of the stuff the UPS babe on wheels delivered…

 

[Rezarf <><]

Have fun making it yours! You've got a great canvas there to do something neat.

 

[Ranchero]

Let the fun begin! - Looking for suggestions

OK - ready to start. FedEx dropped of a new Adventure Trailers combo slide yesterday… Now we can begin.

Let me start by saying that while I'm generally a cheapskate, I'm of the mind of doing it right the first time and making it last. The A/T slide costs a pretty penny but provides a way to fit the most kitchen area in the least amount of space, has easy access to make a quick cuppa joe road or trailside and is of quality that is unparalleled.

I'm looking for your input on configuring storage, domestic water storage and a potential hot water system.

To try to get an idea on how to configure things I've laid out the basic set of boxes and bags that would be in the vehicle for everyday use and on light trips. In the first pic you can see the boxes that would be under the platform. The silver bits sticking up are the approximate locations for the 80/20 legs that will hold the platform up. The basic kit includes: 1. Large Wolf box (comprehensive tool kit to be stored under platform right behind passenger side rear seat. 2. Small wolf box (smaller tool kit, Hi-lift base and mechanism, camstraps, rope, etc.) 3. Small Wolf box (empty now). 4. Recovery gear bag. 5. First Aid bag (stored above platform for easy access). 6. Hi-lift post (maybe - I have the 60 inch version, would have to cut to 46" to fit with all seats in. I don't want a bunch of crap hanging off the roof rack, but I may mount just the post up there. 7. Shovel (may need to go up high too). 8. Small axe.



The next photo is with the set of gear (sans clothing and dry food) that would would have on a normal camping trip. This stuff would go on top of the platform: 1. Wolf box (kitchen #1: basics: coffee, plates, pots, utensils - things used every time cooking). 2. Wolf Box (Kitchen #2: grill grate, large wash basin, larger pans.) 3. Three chairs 4. Tent (4-season in two bags). 5. Recreation goodies bag (baseball gloves, slingshot, frisbees, etc). This gear list assumes we are using a rooftop tent, otherwise add to this three sleeping bags, pads, and pillows. We would still have ground tent for back up in the event we need to stay in a tent site at a public campground or want to hike in to a neat spot.



Water: I'm thinking of using an 15-gallon ABS tank where the spare used to be. I also have space in front of the fridge and have lots of space with the front seat removed. We normally travel with three, but we occasionally have a fourth so it would be nice to have the water elsewhere.

Hot water: I'm thinking of making a heat exchanger (or perhaps buying a Helton) to heat water and store it in a removable module (4 gals or so) where the driver's side rear seat goes. The water loop could be connected to quick releases on the side just in front of the refrigerator to be able to remove the system when I need the fourth seat. Switch to activate flow through heat exchanger just before stopping for the evening.

Pumps for water systems could be located under platform just in front of the refrigerator.

I would love to have your feedback/critique on any of this.

 

[Ranchero]

80/20

OK, here is the basic idea. 80/20 is super easy to work with. This platform is about 1.5" higher than ideal, but I want to wait to get my water tanks situated before I cut the legs. There will be an additional cross brace on the larger part. Will attach with four L-brackets. You can see one of them on the lower left. Should be able to R&R the whole platform in five minutes.

I'm ordering a 4.5 gallon tank for hot water storage just behind the fridge. This will fit under the main platform so I can have hot water even with the 4th seat in. Also ordering a 12 gallon for the main water supply. Will mount this in the location of the stock spare next to the air tank. Where to put the filler for the main water tank? THinking of either 1. to the left of fridge, 2. outside next to fuel filler, or 3, under the fridge slide - looks like I could recess it into the floor and be able to fill it with the fridge slid out. Opinions on location? THe hot tank will fill at the top of the tank via a cut out in the platform in back of the fridge.

Top of platform will by 1/2 ply covered with Monstaliner.

 

[NMC_EXP]

Rancho

One of your last photos shows what appears to be frame made of square(ish) extruded aluminum sections. I saw a similar material a few years ago used to build equipment racks - it was a modular, snap together and strong. I cannot recall the manufacturer.

QUESTION: Can you ID the maunfacturer or supplier of the square aluminum framing material you are using?

Great idea losing the weight. In fact it is good to jettison everything you can do without:

"Perfection is achieved, not when there is nothing more to add, but when there is nothing left to take away."
~Antoine de Saint-Exupery (pilot & explorer)

Jim

 

[freshspecbluegt]

80/20 is the name of the company. I have been thinking of building a cargo box using 80/20 so I'll be following along to see how this works out.

80/20 Inc

 

[Ranchero]

Yep - Freshspecblue GT is correct. It is 80/20. They sell off-cuts on ebay as well (http://www.ebay.com/usr/8020inc). This is the 1.5" stuff. Very beefy. I suspect the 1" would work as well and save some weight. I'm really excited about this build. Should be modular and easy to modify without much effort and additional expense. The initial purchase was a bit spendy though.

 

[NMC_EXP]

freshspecbluegt & Ranchero

That is the material I was thinking of - thanks a bunch.

Jim

 

[Ranchero]

Made some progress this week. Phase one complete

The amount of space underneath is cavernous! I was planning on mounting my freshwater tank where the spare was, but now I'm thinking I'll put it right behind the rear seat.

I used 1/2 ply for the top, coated with two coats of oil-based poly followed by two coats of Monstaliner in desert sand color.

Front driver's side section removes with four bolts attached to main platform. Main platform comes out with 4 bolts as well. Main platform is mounted to floor with riv-nuts.

I'm working on the passenger side platform extension. That seat will likely always be installed.

Here are some pics:

 

[Maverick1701]

subscribing....love the build so far

 

[NM-Frontier]

Looking good! That stove/fridge slide looks very nice, seems like the way to go. Seems like you have a good plan, but have you considered mounting the Hi-lift and shovel on you swing out? (I think I saw one on your bumper, If not disregard!) Having the jack and shovel out side the truck and easy to access means you are more likely to use them when you need them and keeps the interior neat and clean. Keep up the good work.:sombrero:

 

[Ranchero]

Gordon and Maverick - thanks for the comments.

I've had the hi-lift mounted on the swing out. Last time I tried to use it a pin was frozen. Same thing the time before that. I'm thinking that moving it inside - at least the ratcheting part - might keep it in better shape. But I'm still undecided about that. The other motivation for moving it off the swing out is the weight. I often travel with three mountain bikes mounted to the receiver on the swing out. The hi-lift weighs about 35 pounds which is about 8 pounds more than my heaviest bike. I'm not sure how much weight a Slee bumper swing out can handle, but mine sometimes has about 100 pounds of bike and rack and a 305/70/16 on a steel wheel plus the hilift.

I do think I will put the shovel up on the roof rack. Do you think quick fists will work well enough for that?
Steve

 

[Ranchero]

platform finished

Super busy winter and spring at work. I'll post some updates.

I finally finished the platform. After CruiseMoab I realized that I needed to do something to make the area to the left and on top of the fridge more useful. I built this cover out of aluminum. It attaches to both the base of the slide and side of the platform. It's super rigid now. I can lash stuff on top and the fridge can now be pulled out even when the rig is fully packed, which it will be for the next six weeks for our trip to Alaska.

I've also installed a 12 gal cold water tank behind the seat and a 4 gallon hot water tank in front of the fridge. The hot water is linked to a heat exchanger under the hood that can either heat water in the tank or pump from a bucket and out to shower connections at the bumper. I'll post pics of the water system soon.

 

[skivan]

very cool. i have a syncro westy and just picked up a cruiser too (100 series…more as a dd).

the AT stove/fridge slide would actually go great in a weekender van, right behind the pass seat. it could slide out, and would be a perfect outdoor kitchen under an awning. i haven't seen that, but don't love cooking inside the van anyway.

anyway, cool stuff. keep it up.

 

[Ranchero]

very cool. i have a syncro westy and just picked up a cruiser too (100 series&#8230;more as a dd).

the AT stove/fridge slide would actually go great in a weekender van, right behind the pass seat. it could slide out, and would be a perfect outdoor kitchen under an awning. i haven't seen that, but don't love cooking inside the van anyway.

anyway, cool stuff. keep it up.

Excellent idea. I agree. I only use the stove in the westy camped at ski areas in winter. In summer I cook outside. I would trade mine for a weekender for sure!