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92 Jayco Sportster 8' rebuild in the States with support from Deutschland

92 Jayco Sportster rebuild slide in camper truck camper

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#11 Wandering Sagebrush

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Posted 20 April 2019 - 03:27 AM

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#12 Manfred65

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Posted 20 April 2019 - 03:15 PM

Hi Cory,

 

thanky you very much for the "Blumen". We started like you but our intention was:

 

If we donĀ“t finish the project we know how these campers are built and may start a home- DIY-build for us.

2 Friends offered us a total of 2.5 gal of gas to set it on fire....

 

Today, after starting a camper import business ( Palomino, TravelLite and starting last December, BundutecUSA) this eperience is a great help for us!

 

We follow your build and i will try to jump in if i think it can help.


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2000 Ford F-250 SuperDuty SC LB 7.3 Lariat
1992 Jayco Sportster 8ft Popup

http://www.wanderthe...8ft-renovation/

BundutecUSA, TravelLite and Palomino TruckCamper Sales in Germany and Europe

 


#13 corybrown50

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Posted 20 April 2019 - 07:09 PM

Fantastic my German Brother! Looking forward to the adventure for sure.
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#14 corybrown50

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Posted 24 April 2019 - 12:35 AM

Well, got a bit done tonight. Removed almost everything from the passenger side. I was able to start replacing the wood at the rear door. This thing was definitely not made on a jig. Measuring the height at multiple places gave me different lengths. I know some could be due to age and damage, but the gaps in the wood between pieces tells me how slapped together these were. Also, they definitely rely on the plywood for structural strength. I did make the mistake of raising the roof without the exterior on.....oops....I had to add a temporary clamp to hold the roof lift system from boinging out.

My enthusiasm did gone down when I pulled the plywood off the lower side and the whole side dropped 6" to kiss me on the head. Everything is connected and reliant to each other.

With that and my compressor limitations I wasn't able to get as much done as I wanted. Hopefully the weather holds off and I can make some progress. At one point I was cutting off the mounting and jack hardware with a cut off wheel and the wood began smoke.....since I don't have any insurance on her yet I figured a little water was in order to put her out, but I questioned it for a second after just being "kissed" on the head by the passenger side  ;)


Edited by corybrown50, 24 April 2019 - 12:50 AM.

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#15 corybrown50

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Posted 24 April 2019 - 12:46 AM

ARRRGGHHH....I continue to have trouble with Tapatalk getting the images posted on the forum, so I have to do it on the desktop....

 

33809935988_0e222bd049_o_d.jpg

 

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Clamping lift system to "RAISE THE ROOF" with the exterior off

 

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The blank slate for rebuild inside. Lovely blue sky outside :P

 

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3 way fridge removed for "dorm" fridge later.....contemplating a Coleman 12v/110v too. I have both. 

 

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FRESH WOOD!!!!

 

 

Please let me know that you can see the pictures....I'm still learning. 


Edited by corybrown50, 25 April 2019 - 04:19 PM.

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#16 corybrown50

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Posted 24 April 2019 - 12:54 AM

A side note though that did add to my enthusiasm......a friend of mine works at an RV dealer....He sent me a picture of a Jayco that they got in over the weekend. Same "design" but an '04. They turned around and sold it that afternoon for $8000  :o

 

If an '04 with no repairs or inspection can sell for $8000, what is one that has been rebuilt from the ground up worth?


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#17 corybrown50

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Posted 24 April 2019 - 02:34 AM

Manfred.....if you see this, can you share with me how you removed the cabover support from the sides without removing the interior?
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#18 Manfred65

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Posted 24 April 2019 - 12:45 PM

HiCory,

i can not see the pics at all. If you want to show me some special problems you can e-mail me at

manfred.klement@goldmail.de. 

 

As i remember the cabover support was only fixed with some staples. The frame holds the camper together. The support only sat between the horizontal frame parts. Where the support is located the vertical frame is only half the thickness.

On the pics you can see that we did not remove the cabinets.

 

Btw: The rear parts was never symetric. the left winf was closer to the truckbed-sidewall than the right approx 1".

 

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2000 Ford F-250 SuperDuty SC LB 7.3 Lariat
1992 Jayco Sportster 8ft Popup

http://www.wanderthe...8ft-renovation/

BundutecUSA, TravelLite and Palomino TruckCamper Sales in Germany and Europe

 


#19 corybrown50

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Posted 24 April 2019 - 02:29 PM

Well, let's try again....

 

46771473425_7e97c095f0_k_d.jpg

 

Inside cleaned out for new install....

 

33809936458_ee6ab0ef24_k_d.jpg

 

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New wood....

 

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RV fridge removed

 

33809935988_c09fffd1a0_k_d.jpg

 

Clamp for lift unit....hopefully I'm figuring out the issues with pictures.


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#20 corybrown50

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Posted 25 April 2019 - 12:35 AM

Well, got a bit more done today. A note to anyone who takes on an endeavor like this. Study the way it is put together first before digging in. My biggest mistake is that I dug into the back and side before replacing the cab wall. I needed to replace that wall first. Unfortunately, now I'm dealing with instability and having to support everything.

I did get a bit done though. The rear wall is replaced now. The lower wall on the passenger side is in. The rest of the passenger wall is off.

I didn't realize how much rot and damage I would have to spend time with. I'm really glad I have a cut off wheel, as all the hardware except 2 bolts had to be cut out as all the t-nuts just spun in the rotten wood.

Next step is getting the cab wall removed, then rebuild the passenger wall, then the cabover I think.

New back wall....
New inside wall.....
The pile grows......

 

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Edited by corybrown50, 25 April 2019 - 04:22 PM.

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