US 2WD NRR Build In Progress

[CowpokePaul]

Thanks to this site for auditing my plans on paper and giving me the confidence to dive into a box truck camper build without having any clue what I'm doing. I wish we could get the 4x4 NPS in the U.S., but we went with a 2WD for our build with intent to haul 2 ADV motorcycles to target the trails. Hope it works out. Thought I'd post some pics for fun and see what hints/tips/advice come up.

End layout first:


Hauling a BMW GS adventure and a Honda CBX 500. No crawl-through cab. Hapijac bed lift in the back over the "garage" - bring down when bikes out. Small kitchen in front, 2 dinettes that also fold-down into single bed. 45gal fresh water. 800ah batteries & 1600w solar.

The build has started but progresses very slowly. Working from the outside-in.






Garage in rubber diamond plate with e-track down. Have wheel chocks and o-rings for motorcycle tie-down. The rear door is a fold-down ramp; a little scary steep to drive the big bike into, but it works. Bought a "drill-winch" (which I haven't tested yet) to support slower guided haul into place for both bikes.

Solar, 12v A/C install, fan install, and pre-wiring next. Fingers crossed I can finish this thing by Fall... may be doubtful. But should be fun when she's all said and done!

 

[SkiFreak]

One concern I would have is the smell of the rubber mats in a confined space used for sleeping.
Maybe your mats do not smell, but all of the ones I have had experience with in the past did.

 

[CowpokePaul]

I’ll let you know! The work has mostly been in the cold so alfar sand with doors open, so we hav’t noticed it yet. It’ll air for likely a year before ever travel in it - the build is slow going. I hope it won’t be bad. We’ll see.

 

[SkiFreak]

As I am sure you know, not all rubber mats are the same.
Some lose, or lessen, their smell over time, but I have floor mats in my workshop that still smell much the same as they did when they were new, and they're over 10 years old now!
In a large, airy space, this is not normally an issue, but in a confined space that may not be the case.
But as you said... you'll find out.

 

[CowpokePaul]

This could end up being a newbie mistake for me. I think ‘odor management’ in general wasn’t much on my build radar.

This is a Morgan Proscape box that is normally used for lawnmowers & stuff; there are 4 vent boxes, 1 at each corner. When we eventually put the walls in, I had thought to sort of fashion a removable ‘plug’ that would allow access.

We’ll be hauling motorcycles in the back; I think gas/oil will also be somewhat of an issue. Maybe I can hook a CPAP to a scuba tank or something.

We have a Maxx air fan going in; hoping I can pull fresh air in and odors out. My wife is keen on this idea, and not for motorcycle or rubber mat issues.

 

[SkiFreak]

You may not have an issue; I was just pointing out a potential problem.
A simple test... shut the box up overnight and when you open the access door in the morning you'll know straight away when you walk in.

 

[CowpokePaul]

Long time no post... but making some progress with this Isuzu NRR build!
Pictures in a shakedown run of the rig at about... 60% complete? Two bikes secured in the garage section to e-track (works great). Awning out and enjoying camping at a stopover point in a state park near Asheville, NC (where we ran into a bunch of hippie bus builders). And the last pic of progress at the FRONT of the box (near the cab) where we have cabinets, sink, and a gas hob installed. Plumbing is run behind the walls to the sink and outdoor shower, stubbed out the location where we'll run fresh tank, water pump and (fingers crossed) Truma Combi 4E boiler. Time to order the Happijac and get the elevator bed build above the garage to have sweet zzz's after the bikes some out.
We installed 8 200w solar panels, a Maxx Air fan and a Dometic RTX2000 on the roof. We did some amateur pre-wiring, but eventually outsourced the build of the Electrical Control Cabinet [ECC] to an awesome RV shop in Knoxville, TN. They put in Victron gear: Multiplus 3k inverter, MPPT 250|100 Solar controller, and an Orion 30A DC/DC charger. Combined with 2 400ah VoltGo batteries tucked under the dinette... we have power for DAYS. Ran the A/C continuously from the afternoon overnight and hit only 70%. Fully topped off on solar alone by the next night. #Overcharged.

FYI - the ramp into the back of the truck is OK, but a little steep... I have ridden up the ramp but there's a place where feet don't touch. We used a drill-powered winch against a pipe stub connected to the e-track as a winch point - it worked PERFECTLY. making progress!

 

[gator70]

Tell us about the progress

 

[CowpokePaul]

Not too much more since the last post. Cabinet doors are in. We had to get confirmation from ‘Truma engineering US’ that they would sell us a unit, but we got that confirmation.

Trying to reach Lippert tonorder the Happijac and waiting to get the Truma unit located, ordered, and scheduled for install.

After that, it’ll be Happijac install, bed frame build, and then largely just finishing furnishing and decor.

Thanks for inquiring!

 

[CowpokePaul]

Folks - I think we're "done!" Well, as much as "done" ever really means in builds like this - always something else to tinker with. Turned out well, we think, but the proof will be in the miles to see how sturdy and earthquake-resistant she turns out to be.

A few notes:

* 2023 Isuzu NRR Diesel Crew Cab + 16' Morgan Proscape Box w/ fold-down ramp
* Two roof racks on 500lb rated retrofit van ladder rails
* 1600W Solar feeding 800ah LiPO batteries
* Victron gear with 30a shore power inlet, DC-DC charging and a single series MPPT (big one)
* 45g Fresh Tank, 36g Gray Tank, Casette Toilet Only
* Grey Tank rigged to solenoid control in cab for "james bond" oil slick surprisees for close tailgaters (seriously)
* Queen bed mounted laterally on Happijac
* 2 Dinettes 36" width that transform into additional twin bed
* 92" counter and cabinets at front, propane gas hob
* 19" top-mount stainless sink draining into grey tank under cabinet (all plumbing & tanks interior)
* Pex-A plumbing + SeaFlow water pump
* Webasto Dual Top ST6 diesel heater + boiler combo
* Rear 8' under the Happijac is "garage" space w/ 2 E-track strips mounted to secure two motorcycles (works great)
* 3 exterior truck boxes underslung
* ARB Awning, External shower, mounted cook table, and 12V+USB outlets
* Cheap HD cabinets (painted), rubber diamondplate flooring in garage, LVT in front half

I think that's about all I can think of! It's been a little over a year in the build all on weekends and holidays. We did opt for professional installation of electrics and final plumbing/heater (safety investment).

Can't wait to take it on our first really long family trip coming up over the holidays. Hope she holds up!

If I can help anyone else looking to do something similar, please let me know - this community has been so helpful and encouraging to me, I'd love to pay it back (if I can).

 

[CowpokePaul]

@Gdietz - this one is for you! See above.

Oh, and we did our final measurements yesterday:

Height: 12' 0"
Length". 26' 0"
Widgth (mirror to mirror): Approx 8' 6"
Weight: 15,400lb

When we ONLY had the floors in and had stripped all of of the initial plywood off the walls it weighted in at 11,100. I can't believe we added TWO TONS of stuff into it. I'm sure it could be done lighter. I think the 1/2" tongue-in-groove walls added way more weight than expected... but the wife wants what the wife wants. GVWR is 19,500 - so we've got two tons to spare. + full Fresh + Bikes it'll be 16,800.

Welcome to 4mpg, I guess. We've been getting 8 (rated 10) pushing higher speeds. Hoping to reclaim a little mpg with more reasonable speeds on this upcoming trip.