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Rnk's Hawk shell build

Hawk shell build

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#1 RnK

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Posted 19 December 2014 - 03:23 AM

Hi everybody,

 

With our Thermal Pack built and tested (write-up here;   http://www.wanderthe...mal-pack/page-2 ) we seem to be about 95% done with all we had planned to do. 

 

We started with this setup;

 

2004 dbl cab Tundra with RideRite airbags

 

gallery_5403_824_69918.jpg

 

 

2014 Hawk shell with these options:

 

     2 Solar plugs

     12v outlets

     Furnace and propane

     Fantastic fan and extra roof vent

     Rear wall steps

     Additional driver's side window

     Privacy curtains

     Aux. battery system

     Gas struts (4)

     Jacks and brackets

 

Looked like this inside;

 

med_gallery_5403_824_40293.jpg

 

 

med_gallery_5403_824_2329.jpg

 

 

med_gallery_5403_824_23290.jpg

 

 

Knowing we were going to build a front dinette, we didn't want the wall cabinet to be in the way of getting in and out of the passsenger side seat.  I pulled it off and cut it down and remounted it.

 

med_gallery_5403_824_17262.jpg

 

 

I had to create a table for the dinette and I wanted it to match the counter top over the heater.  I had enough Formica laying around to do the job so I unscrewed the counter top (with some difficulty as I did not want to remove the heater and it is screwed from below)and removed it.  While I had it off I installed a voltmeter (detailed here;   http://www.wanderthe...hole-voltmeter/ ). Then I built a slightly larger top and installed it.

 

gallery_5403_824_27055.jpg

 

 

Next I added the seat buildout out of 1/2" birch plywood with maple rails.

 

gallery_5403_824_9983.jpg

 

I had to cut down the long narrow door over the stock storage area in order to accommodate the new larger door created by the seat buildout.

 

Here is the door closed,creating the seat.

 

gallery_5403_824_19207.jpg

 

We bought a sheet of 4" decent quality foam online from the Foam Factory and ordered fabric to match our existing upholstery from FWC.  We cut the foam to fit our needs and hired a local woman to sew it all up for us.  I made plywood backs to go behind the seatback cushions and extended the upper bed slide out rails for them to lean against.  I bought a different thermostat at Amazon (http://www.amazon.co...2190_TE_3p_dp_1) as the one that came on the Hawk came with a setpoint that was too high for our needs.

 

med_gallery_5403_824_9473.jpg

 

It had to be moved up a little to accommodate the rail extension.

 

So here is the finished product:

 

Seatback with a bolster behind creates the proper seating angle, at least for us.  I used our dining room chairs as a template of sorts.

 

gallery_5403_824_24660.jpg

 

 

The result is a seat that is comfortable for sitting at the table,

 

gallery_5403_824_37781.jpg

 

or it can be turned the other way for lounging for her on the driver side,

 

gallery_5403_824_40580.jpg

 

or me on the passenger side.

 

med_gallery_5403_824_34965.jpg

 

 

I raised the floor between the seats so our legs wouldn't dangle while sitting and created some storage underneath.

 

med_gallery_5403_824_6020.jpg

 

NorCalHawk was kind enough to send me the table supports he was no longer using so building the table top was straightforward.  I used formica on the underside of both the table and countertop, the former for strength and the latter because that's the way FWC does it (I assume for heat protection in the heater area?).

 

The dinette makes into a comfortable bed for one person.

 

gallery_5403_824_13358.jpg

 

 

And finally, we had a receiver hitch step made by a local welder.

 

gallery_5403_824_11462.jpg

 

The foam and reflectors are ours.  Had to move the license plate up a few inches to make it visible.

 

Costs, roughly, so far:

Plywood,glue,misc.            $130

Misc. hardware                  $ 65

FWC fabric (&vinyl)           $206

Seamstress                       $200

Thermal pack mat.             $215

Misc other                          $ 25

Thermostat                        $ 50

 

Rough total                        $676

 

 

So, there it is.  Many thanks to all the contributors that gave us so many great ideas.

See you out on the road!

 

R and K

 

 

 


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2004 Tundra 4x4 Dbl. Cab

2014 Hawk Shell


#2 Wandering Sagebrush

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Posted 19 December 2014 - 03:32 AM

I think you did a good job. Looks nice. Feet off the upholstery though:-)

Edited by Wandering Sagebrush, 19 December 2014 - 04:18 AM.

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#3 billharr

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Posted 19 December 2014 - 03:34 AM

Nice job, you will enjoy having the camper the way you want it.


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#4 camper101

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Posted 19 December 2014 - 03:32 PM

That's great - I like the lounging option.


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2012 Eagle Shell with a few extras


#5 super doody

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Posted 20 December 2014 - 06:30 AM

RnK,

 

Great write up! And very helpful! Curious about how you guys pack your camper for a trip.  Do you guys have plastic bins to hold stuff such as stove, bbq, cookware, and food?

 

This is what had to do with my Eagle Shell which worked okay but it was PITA if I wanted to get something in the camper mid travel:

 

http://www.wanderthe...de-eagle-shell/

 

Do you plan on relocating the battery in the future?


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2003 Tacoma 4X4 - 2007 FWC Eagle shell

2006 Tundra Double Cab - 2015 Hawk - side dinette, silver spur interior


#6 craig333

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Posted 20 December 2014 - 07:42 AM

Looks good. 


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#7 longhorn1

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Posted 20 December 2014 - 01:04 PM

Nice Job.  You will enjoy every minute.


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#8 RnK

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Posted 20 December 2014 - 05:59 PM

RnK,

 

Great write up! And very helpful! Curious about how you guys pack your camper for a trip.  Do you guys have plastic bins to hold stuff such as stove, bbq, cookware, and food?

 

This is what had to do with my Eagle Shell which worked okay but it was PITA if I wanted to get something in the camper mid travel:

 

http://www.wanderthe...de-eagle-shell/

 

Do you plan on relocating the battery in the future?

 

 

We haven't got all that lined out yet - still organizing and experimenting.  We'll get serious about it after the holidays I think.

No plans to move the battery, though I suppose under one of those seats might be a good spot.  Hmmmm....

 

 

A note on the rough costs - a little too rough - actually adds up to $891.  Ooooops

 


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2004 Tundra 4x4 Dbl. Cab

2014 Hawk Shell


#9 GroovyDad

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Posted 21 December 2014 - 04:15 AM

Very nice looking build.  I especially like the versatile design of the front dining table.  Do you all do any cooking inside?


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#10 RnK

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Posted 21 December 2014 - 02:43 PM

Very nice looking build.  I especially like the versatile design of the front dining table.  Do you all do any cooking inside?

 

 

We make coffee in the morning inside (if it's cold out) on a one burner Coleman but cook our meals outside.


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2004 Tundra 4x4 Dbl. Cab

2014 Hawk Shell






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