Suzuki Samurai Custom Camper Build

trackhead

Adventurer
i know im a little too late, but you should have extended the rear frame and pushed it all back about 5 inches. i am on my 8th sami, and they really do a lot better with a little more length.

but, i think this is a cool concept. keep up the good work.

I thought about doing that, but I just sold my motorhome, and the idea of this build is the extreme opposite of a motorhome. I want it to be light, small. I also don't have the welding skills or really knowledge of autos to pull that off. Rebuilding a motorcycle, no problem, but auto's are new to me. Trying to stay as stock as possible to stay within my limited realm of knowledge. Plus, I want to eventually put Tatou tracks on it, so light will be important.
 

trackhead

Adventurer
Worked a bit today on the bondo/smoothing/sanding. Seems to be working well by sanding endlessly with 80 grit, then 120, 220, 400, and eventually 800 I guess. After my arms fall off from sanding it looks like filling the pin holes with Evercoat, then more sanding, then polyester primer/paint.

Here's a section of bondo/glass. Haven't put much time into it, but it is smoothing out nice. Obviously plenty of pin holes and tons more sanding to do.
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Backroad Explorer

Adventurer
trackhead; OHH MAN is it going to look good when it's done. I think all the effort will be worth it. Any pic's from the side possible? I may have missed it but what part of this country are you in? Again Great Work :bigbossHL:
 

trackhead

Adventurer
trackhead; OHH MAN is it going to look good when it's done. I think all the effort will be worth it. Any pic's from the side possible? I may have missed it but what part of this country are you in? Again Great Work :bigbossHL:

I live SLC, UT.

Goofy looking rig, looks like a convoluted dump truck. It looks a little less goofy with the roof on. The idea behind the shape was this, I wanted to keep the short wheelbase and not have the camper extend over the front of the cab for wind resistance reasons, nor off the back to get crushed on a rock. I needed to make the top at least 65" long for my wife and kid, and I will sleep below on a fold out bench.

Ugly, not sanded. Still have to cut a hole for the gas cap. Brown area will be a 15x24" window next week.
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trackhead

Adventurer
Got the right side sanded to 80 grit and the gas cap installed. My arms are going to fall off from sanding.

Still have to sand around the gas cap opening.
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trackhead

Adventurer
Got the camper rough sanded today and a rough cut of the roof done. My arms have fallen off.

Plenty of photovoltaics.
IMAG0644.jpg


Still have to sand the front of the camper, then more sanding with 120, 200, 400, 800, etc. Then a ton of work on the roof mating edges, more glass, etc, etc.
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Windows should be here tomorrow. In the meantime, this is the pile of sanding debris from today. The rest is in my hair, nose, mouth, eyes, ears, and lungs. Despite wearing a nice respirator...................
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trackhead

Adventurer
Got the windows in today and the back door rough cut out.
IMAG0663.jpg


Now it's time to work on the roof, then more sanding, then the rear lights. After all that, hopefully paint it, then spend a couple weeks putting new transfer case gears in, new lifted springs, etc.
 

trackhead

Adventurer
I sure hope you have a DA air sander trackhead. Windows look great. Are you going with the wilderness style top?

Yeah, I ended up buying one, but I still need to finish with a block sander by hand to get it as smooth as possible.

Decided against the Wildernest style flip out, too much weight to get the bed strong enough. Doing a pop up, mini-wildernest bed type thing.

Might get slowed down on progress with my wife popping a little one out probably tomorrow.

You have a Thiokol Imp, eh? Cool snowcats. I owned a little Bombardier Bombi for a while, but I'd like to get an Imp or Super Imp at some point in my life.
 

trackhead

Adventurer
Only getting an hour or two a day to work on it with the newborn, but getting closer.

Still need to do a ton more sanding, mount the door, add another layer of glass to the interior of the roof, then work getting a clean mating surface between the pop top and the main camper.
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