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84 Fleet - 09 Tacoma - Project


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#91 Living The Dream

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Posted 10 June 2017 - 07:36 PM

Passthrough lids

A quick project that I could check off the todo list one afternoon.  I used some spare plywood and left over panelling to make new passthrough lids.  Three passthroughs are just holes in the top that are easy to put a lid on.  A little glue, a quick clamp, some paint, and voila a lid.  I did use a bit of weatherstripping to help with sealing out the cold air.  I will add some sort of latch in the future but that is low priority.

 

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The last passthrough was slightly more complicated as it accessed from the side. But I added a two hinges and all works well.  

 

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I like projects that are quick and easy :)

 

For reference this work was completed in December 2016


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My youtube channel about my Four Wheel Camper - https://www.youtube.com/c/timmorrissey

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Item I used in my build- http://bit.ly/TGMorrisseyParts


#92 Living The Dream

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Posted 10 June 2017 - 08:18 PM

EMT roof lifters

I put this project off as I was a bit afraid to tackle it.  It took me quite a few weekends but in the end came out great!

 

As I have discussed in the past I just didn’t want to buy the new composite panels because of the price. But also because I wanted to add more height to my interior ceiling.  Since I am making the canvas I have that option and ended up going with a 6’6” interior height!  No more ducking around inside the camper.

 

It is pretty tricky to figure out how to get the pivots location correct, bend the conduit at the right spots, etc.  I do have a ton of measurement sketches but will opt not to post those as I did a lot of shooting from the hip as I progressed.  One thing you need to make sure of is that there is room for the top horizontal tube when in the down position. To accommodate that you need to have your lower pivot be below the camper body top.  I think the pictures will help clarify.

 

1st bending the emt, I got pretty good at this by the end. My main suggestion, use a level and level ground to tweak all the angles to 90.

 

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Then it was time to figure out the the lower pivot system.  Like everything on this camper it was time to learn some new skills.  After trying a few different options with stock parts from the hardware store I finally just made my own brackets.  A friend lent me his shop and I cut the sheet metal and stock with the bandsaw and shearing machine. Didn’t do 100% perfect but I got the job done.

 

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There is a lot of pressure down at that lower pivot so I wanted it really secure. That is why I made these spaces and the oversized brackets backing panels to really tack the pivot bracket to the side wall.  Some other things to look out for it to make sure the tube has clearance away from the wall to make the rotation. If you want to go this route just get in touch with me and I can try to offer more advice.

 

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It was pretty cumbersome and stressful to get it all in place and together. Took a lot of guess and check but eventually it went together nicely.  And hey it works!  Fits in both the up and down positions.

 

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And of course after I knew it worked, I took it all apart and painted it to match everything else.  I also used some table end caps to give the tube a finished clean looks

 

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The middle pivot and locking pin

 

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The top support attachment just uses stock emt hardware.  Three on each side.

 

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It was a tough problem to solve but very doable.  I would suggest this to anyone doing a rebuild and not wanting to but the panels from the dealer.

 

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Something I will need to deal with in the future is that in the bed area the lifters take up a lot of volume in the down position.  I might have to put mattress down to drop the roof.  A bit of annoyance but I will cross that bridge when i get to it.

 

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But look at all this headroom!

 

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For reference this work was done in January and February of 2017.


Edited by Living The Dream, 10 June 2017 - 08:18 PM.

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My youtube channel about my Four Wheel Camper - https://www.youtube.com/c/timmorrissey

All about my camper - https://www.tgmorrissey.com/camper

Item I used in my build- http://bit.ly/TGMorrisseyParts


#93 Living The Dream

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Posted 10 June 2017 - 08:39 PM

Bed pull out

Another rather quick few-evening-task was the bed pull out. There was a nice piece of ¾ in plywood that was with the camper when I bought it, so I kept that.  A little sand, stain, poly and it looked great.  

 

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I had some left over UHMWPE from another project so I made four slide bars to try to reduce wear on the wood.  I counter sunk the screws and used glue when I installed them to the bottom of the pull out.

 

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I also rounded the corners with a jigsaw so they fit into the camper closer. This allows the bed to be pushed in fully when in the closed position and won’t bother someone sitting on the bench with their back to the bed.

 

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Then I just installed the supports on the wall just like what was there before.  I think FWC still uses this type of support today.

 

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There is support along the front wall too.

 

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Pulled out

 

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I still need to make a front finish piece like what Poky just built.

 

https://www.wanderthewest.com/forum/topic/12116-new-build-1981-grandby-to-become-a-hawk/page-20

 

That piece is definitely important to give the plywood extra rigidity.  I’ll be sure to finish that off nicely in the near future.

 

For reference this work was completed in January or February 2017.


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My youtube channel about my Four Wheel Camper - https://www.youtube.com/c/timmorrissey

All about my camper - https://www.tgmorrissey.com/camper

Item I used in my build- http://bit.ly/TGMorrisseyParts


#94 Living The Dream

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Posted 10 June 2017 - 09:15 PM

Rebuild door

The ski season might be winding down, but bike season is kicking up and just as distracting.

 

 

I was going to start the sewing project, finally, but had a few set backs so I took care of one more issue that was nagging at the todo list.  The old door was in tough shape! The bottom piece had rotted off, someone had obviously tried crowbar in at one point in time, the door just needed some love.

 

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I took everything apart and used the old frame as my template.

 

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I recently got a new saw so I also built myself a little cross cut jig.

 

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With a bunch of clean square corners thanks to my new saw, the frame came together in a snap.

 

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With the door being a unique thickness I had to improvise for the insulation which I was able to do with some reflective and 1” rigid foam.  It actually worked out really well.  A quick note, 3M 90 adhesive will eat rigid foam insulation.

 

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I did a little JB weld/beer can (La croix)  fix in an area of the sheet metal someone broke before.

 

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Then it was time for more paint.

 

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And the final product came out awesome.  For some reason I was really excited how this came out.  Really a nice finished look and very motivating to push through to the near end of this project.

 

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We made the inside an accent color and it stands out really well.

 

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This work was done this week, June 2017.  Back at it with night and weekends.  I swear the canvas liner will be my next project.  Or maybe I will get distracted with the electrical :)


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My youtube channel about my Four Wheel Camper - https://www.youtube.com/c/timmorrissey

All about my camper - https://www.tgmorrissey.com/camper

Item I used in my build- http://bit.ly/TGMorrisseyParts


#95 Living The Dream

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Posted 10 June 2017 - 09:16 PM

I have a friend in NC that had a commercial sewing business. He still has a few machines and he said I'm welcome to one. It does need a motor, as it has a 3 phase motor on it now. I'm going to buy a motor and have it shipped to him, about $120.00. Once he has it set up. I'll go get it, and get a little fishing in at the same time. Shame we aren't closer and could share it. I'm going to order a little extra material and give a try at the windows. If I make a mess of my sample, I'll just go without the windows. Another alternative is to have a friends wife do the windows for me. She has a sewing and embroidery business.  

Shellback, did you ever get the machine and tackle the project.  Would love to hear an update.


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My youtube channel about my Four Wheel Camper - https://www.youtube.com/c/timmorrissey

All about my camper - https://www.tgmorrissey.com/camper

Item I used in my build- http://bit.ly/TGMorrisseyParts


#96 Living The Dream

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Posted 10 June 2017 - 09:18 PM

First off, all the guys that came up with these lift tubes, great idea! One thought I had was installing them East and West. Phoenix uses a system like that but has tracks on the roof. If you used your system but side to side with the struts still North South it might work and not encroach on the cabover bed.

Just a thought for discussion.

 

Here's the link to the phoenix lift bars:

 

Hey Lindy,

 

Yes I have seen them in the other orientation; both in the Phoenix and also in some custom van pop ups.  I just updated with a post detail my new lifters.  I am happy with the North South panels but would love to see yours if you go with something else.  - Tim


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My youtube channel about my Four Wheel Camper - https://www.youtube.com/c/timmorrissey

All about my camper - https://www.tgmorrissey.com/camper

Item I used in my build- http://bit.ly/TGMorrisseyParts


#97 GoinBoardin

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Posted 11 June 2017 - 06:58 AM

Thanks for updating. I too am a grad student (just north of you in Wyoming), rebuilding an old FWC, but being distracted by biking and earlier in the year, snow fun (snowmobiling). I'll be following your foot steps on the EMT lift mechanisms very soon (exterior canvas is here, new headliner on the way) and appreciate your detailed pictures & tips. I recently built a slide out bed just like Poky's too. Just wanted to say, keep it up and thanks for sharing! 


Edited by GoinBoardin, 11 June 2017 - 06:59 AM.

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#98 Living The Dream

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Posted 11 June 2017 - 08:28 PM

Thanks for updating. I too am a grad student (just north of you in Wyoming), rebuilding an old FWC, but being distracted by biking and earlier in the year, snow fun (snowmobiling). I'll be following your foot steps on the EMT lift mechanisms very soon (exterior canvas is here, new headliner on the way) and appreciate your detailed pictures & tips. I recently built a slide out bed just like Poky's too. Just wanted to say, keep it up and thanks for sharing! 

Thanks, glad you are tackling a project too. Would love to see your build documented too!  Let me know if you have any questions.


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My youtube channel about my Four Wheel Camper - https://www.youtube.com/c/timmorrissey

All about my camper - https://www.tgmorrissey.com/camper

Item I used in my build- http://bit.ly/TGMorrisseyParts


#99 Living The Dream

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Posted 13 June 2017 - 02:11 AM

Quick lights install.

I did a bit of work this weekend. Besides sketching out the rest of the canvas sewing plan, I installed my four overhead lights.  I bought these 12 V LED replacements a while ago.  The amazon link is dead but this was the product information:

 

YITAMOTOR 10 X 1156 BA15S 68-SMD RV Camper Turn Signal Warm White LED Light bulbs 1141 1003

 

I am very happy with the lights.

 

A couple of butt crimps and we were good to go.  Easy peasy and have a ton of light.  These photos were taken in the garage with all other lights off and doors closed.  With all 6 lights I was still only pulling 1.6Amps which means I will definitely be good for many days even without any solar.

 

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I swear I’ll sew my canvas soon.

 

For reference this work was done in early June 2017.


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My youtube channel about my Four Wheel Camper - https://www.youtube.com/c/timmorrissey

All about my camper - https://www.tgmorrissey.com/camper

Item I used in my build- http://bit.ly/TGMorrisseyParts


#100 ski3pin

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Posted 13 June 2017 - 04:26 AM

Your work is fun to follow. Thanks much for the updates!
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2003 Ford Ranger FX4 Level II 2013 ATC Bobcat SE "And in the end, it's not the years in your life that count. It's the life in your years."- Abraham Lincoln  http://ski3pin.blogspot.com/





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