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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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#21 Manfred65

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Posted 25 April 2019 - 12:22 PM

You have a lot of firewood out there....

Paint the exterior wood ( covered by the aluminium later ) with some wood protect paint. We used special covered wood from kitchen furniture for it. And VERY IMPORTANT: Give all the regions around the roof lift some extra layers of paint and keep an eye on these spots later. The roof lift is located outside the canvas and rain water always comes inside along the lift mechanism. This is one of the reasons for the desaster in the corners.

Edited by Manfred65, 26 April 2019 - 12:26 AM.

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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

 


#22 corybrown50

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Posted 25 April 2019 - 04:12 PM

A great point sir.....I was surprised that the roof lift system did not have screws in it to hold the tops down. I may try to figure out some sort of rubber boot for the area as well. 

 

Yes, luckily I live in a "township" where the burn rules are a bit more lenient. 

 

Rain today and men's group tonight for church. The deadline I have is fast approaching and I'm a little scared I won't get it all done. I'm leaning on the roof having to wait until after the deadline and hoping for good weather while out with our heavy duty tarp as a safety net if not. 

 

The truck is also giving me issues. I had to replace my transmission lines and they are not sealing properly. All camper work will be for nothing if I cannot get the truck to haul it. The same friend that works at the RV dealership is also a trained mechanic. Hopefully he'll be able to come over and help soon. I always say having 2 people makes the work go 4 times faster. 

 

On the picture you have with the cutting tool, what are you cutting? Is that just a cut out for support? That board looks much thicker than any that I can recognize. 


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

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#23 Manfred65

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Posted 26 April 2019 - 01:55 PM

Sorry, i am not sure what we ct out at this moment. I think we clamped the plywood that is now the bottom of the cabover storage, on to the frame, marked the cutoutsfor proper fit, did them and pushed the plywood farther to the camper. You can see the gap behind the marked cutout. This is shows the way how far we had to push the ply. After finishing there was everything closed. 

 

Like you i had fun with my Truck along  with the camper rebuild. It sucked the batteries and spit the Diesel back while fuelling. The Diesel issue i found last week after removing the tank 5 times over the years. 


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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

 


#24 corybrown50

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Posted 27 April 2019 - 01:13 AM

Well, I got a bit more done this evening. Looking forward to the weekend as long as it stays dry. I replaced the front/cab wall. One thing that keeps ringing in my head is what Manfred said about cutting after putting the aluminum back on. I'm hopeful that my holes line up in the end.....fingers crossed.....

 

New front wall.....

33831657888_a764bc840d_z_d.jpg

 

Also started the passenger side wall a bit. I think I'll put this back in before diving into the cab over rebuild. I thought about using a 2x4 across the bottom, as this is the side that only has 1 lift, but decided against it. I will do as Manfred did and reinforce the area that the lift is. 

 

33831657858_c9f5601fcd_z_d.jpg

There will be some "engineering on the fly" with the cab over as I plan on putting in a queen mattress, bringing the mattress area into the main area by about 6 inches....I will hopefully be able to re-engineer the support of the mattress, as I am not a small man....6' and about 280#, with the wife up there as well.....and the weight of the mattress. I also plan on utilizing exterior supports on the cab over area when we are set up. The ones I like have a ratchet strap that brings 2 together at the bottom. I have enough scrap around that I should be able to make them myself. 

 

She's coming along at a steady pace....I keep telling myself, "How do you eat an elephant?".

 

I made another mistake, I clad the rear with plywood before adding the final corner piece that is the start of the passenger side wall. Not really worried about it, I can add another piece there, just 1 more thing to add to the learning. 

 

One thing I thought of last night was mounting the LP tank outside, giving myself more storage inside. It doesn't necessarily need to travel outside, but when we set up, I could have a mount to the left of the rear door. Anyone have any issues with this idea? I already need to work on the LP lines, as I have removed the refrigerator and need to remove that branch off. I was thinking I could put in a shut off valve there in place of the T there now. That would allow me to shut off the stove area. I read somewhere that you should have a shut off at junctions anyway. I really like the idea of extra storage, and could replace the door to the LP area with plastic board 1/4" thick and insulate behind.....Just thinking.....

 

Hopefully I'll have a lot more to share tomorrow night. I think I've talked the Mrs. into prepping the aluminum for reinstall. It needs all the putty and staples removed still. 

 

No movement on the truck. The banjo bolt that holds the transmission coolant bypass in leaks. I'll have to deal with that soon, but really didn't want to crawl around on the ground. I need to remove the exhaust heat shield and get in there with a tap to make sure the threads are clean so the bolt can get in all the way, and find some decent crush washers for it. The local auto store wasn't much help with "good" crush washers, as they didn't crush at all. I'm thinking of using copper instead of the factory aluminum, but was told mixing copper with steel and aluminum may cause some electrolysis.....I don't know enough to decide. 

 

 

It still amazes both of us how loosely these were built. Gaps everywhere. Hopefully my rebuild will last another 26 years.....

 

Hopefully my train of thought here makes sense to everyone.....it is a learning project for sure. 

 

Any and all feed back is super and appreciated for sure!!!

 

Thank you all....this forum is AWESOME!!!!


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#25 Manfred65

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Posted 28 April 2019 - 05:30 PM

Hi Cory,

 

i cannot believe that there is only one roof lift on your passengers side? We had two of them on every side...

 

I cannot follow your idea with the cabover support

 

35630086jc.png

 

 

Not a bad idea to leave the propane box out.So you willhave a much better access to the front right roof lift for repairs and moisture check.


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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

 


#26 corybrown50

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Posted 29 April 2019 - 12:26 AM

In adding a queen instead of the full, the bed will extend into the living area the difference. Basically covering the seat/storage area by the cab window.

The 1 lift I wrote of is the lift to pick the whole camper up, there are only 3, 2 on driver side and 1 on the passenger. As for lift for canopy, there are 2 in the rear, and 1 on either side of the camper at the front wall before the cabover area.

As for access to the lift if I more lp to exterior, the area will be storage and I will still leave it open for the lift mechanism, I'll just have to access from the inside instead of exterior. The decision was made already that this is the direction we should go by the Mrs.....so that will be it.

I got a good bit done on it yesterday and will update later with pictures from my desktop. I had to switch gears today and work on the truck more as all the camper work will be for nothing if I have no way of carrying it. The truck work is super frustrating. I have everything correct, but it is still leaking.

Freaking out a lot as there are only 4 days left and I have nothing complete. Weather is also not playing nice with me, as we have rain scheduled every day this week.

If I can get the truck done, I may end up having to rent a camper for the weekend.

The goals are in this order:
Truck
Cabover
Passenger bed side floor
Lift system reinstall
Exterior cladding
Exterior aluminum
Doors and windows and sealing

Biggest hurdles are truck and cabover design. I didn't finish the truck tonight and I think it will be another evening for it. That leaves me with 2 days for the others.


Pray for me to keep my head and focus.
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#27 Manfred65

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Posted 29 April 2019 - 11:26 AM

Ok, got it. There was a misunderstanding roof lift/ camper jacks.

We wish you the very best, even Mr. Hurry is never a good help in repairing tricky things. Build it „ready to go“ this week and finish it later!

Good luck and happy camping!
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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

 


#28 corybrown50

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Posted 29 April 2019 - 03:19 PM

As I said, I did get a bit done on Saturday. The passenger side wall is ready for insulation and cladding. The cabover support is hung. I had a bit of difficulty with the walls on the bed side as I put the bottom vertical wall in first, instead of following Manfred's example of putting the horizontal in first. 

 

47715955421_30873d7191_z_d.jpg

 

The start of the framing in process.....

 

33838723958_eb84c92428_z_d.jpg

 

Double checking that everything is in the right place.....

 

40749520253_77a8933008_z_d.jpg

 

More studs.....

 

47715955851_3a26bdc567_z_d.jpg

 

Finished framing side wall, added extra support where the jack/lift goes. 

 

47715955381_90d9039735_z_d.jpg

 

And lastly with the interior melamine installed. The Mrs. wanted the wood grain gone and replaced with white. This was fine with me as the plain white melamine was less expensive than wood grain anyway. You can see in the corner a hole for the lift system, but I plan on making that bigger with the advise of Manfred for having access for repair/inspection. I used a router to cut the openings for anything I've had so far. It makes a mess with the melamine particles, but it is the most accurate way of getting the opening. I like the clean look. You cannot really tell how clean right now as the particles are sticking all over, but it does look pretty slick. 

 

The bed will overhang in this area towards the window. 

 

Once I get the bed in, things will go pretty quickly with replacing what has already been engineered to fit as is. Big job for the Mrs. is to get all the putty and staples out of the aluminum, windows, and door......

 

I was just told that my daughter has a concert Thursday night......so...... 3 days left.........repair to the truck tonight, hopefully, then 2 days putting this back together. Anyone have any fast drying sealant or little elves I can borrow?


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#29 corybrown50

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Posted 30 April 2019 - 12:45 AM

Well, I spent the evening under the truck and not a good deal. She is not playing nice with me and I don't think I'll make it for the weekend. Well, another deadline I've missed and disappointed for sure.....I'll keep plugging along though. We still want to get out this summer. The short deadline did allow for me to push really hard.....
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#30 Wandering Sagebrush

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Posted 30 April 2019 - 01:24 PM

Cory, nice progress!
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