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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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#61 corybrown50

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Posted 08 July 2019 - 04:46 PM

One thing I forgot to add about the "new to me" truck.....Whenever I get a "new to me" vehicle, I always plan on putting new front end on and brakes, fluids, etc.....I replaced all the steering components, as well as ball joints and control arms....When I replaced the upper control arms, I was looking at it and the angle didn't look right. I matched the control arm that came off, but it just didn't look right....I went to the Moog website to check which side was which as far as part number, and sure enough.....whoever work on it last switched the sides, passenger on the driver, and driver on the passenger......NO WONDER HE HANDLED HORRIBLY!!!! And he has a name....yes, this truck is a he.....The color of the truck is Ford Chestnut....and I am an Ohio State useless nut.....so....he shall be known as Brutus....


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#62 corybrown50

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Posted 15 July 2019 - 02:15 PM

Rocking and rolling here now....good grief....everything I take off adds another day to the process.....

 

Well, let's start simple.....here's the curve for the corners in the cabover....

 

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Adding the front aluminum, I left the front loose so I can add the insulation underneath. 

 

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#63 corybrown50

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Posted 15 July 2019 - 02:19 PM

Here's the insulation. I added double sided foil on each side with some regular styro in the middle. Trying a bit to conserve and reuse there.....

 

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And attached up......

 

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Added the strips and insulation to the front of the cabover area....

 

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With insulation.....

 

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#64 corybrown50

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Posted 15 July 2019 - 02:23 PM

Now for the hardest part by myself.....fighting this thing across the whole edge was a real pain in the bum....getting one side in, moving to the other, then it would fall out....I probable spent 2 hours just getting this piece attached. I really could have used some help here.....

 

Who can spot my mistakes?????

 

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And finally.....the last piece of aluminum from the front.....

 

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Added the front window after trimming the "MISTAKE".....

 

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#65 corybrown50

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Posted 15 July 2019 - 03:01 PM

Well, I took Friday off work to get some more work done on the camper, but first....my little helper and I got to head out to our first daddy/son fishing trip.....

 

FHFH hats for all!!

 

If you don't know about Farmers and Hunters Feeding the Hungry, check us out.....FHFH.org.....We pay for the processing of meat and donate it to local food pantries....really great group. Our chapter that our men's group helps has really grown in the last few years....5 years ago we served around 5000 meals.....last year.....almost 70,000 MEALS LOCALLY!!!

 

Heading out....

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Go this way Daddy!!

 

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Just remember to straight arm the fish so it looks really BIG!!

 

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And the result......

 

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#66 corybrown50

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Posted 15 July 2019 - 03:03 PM

After the morning of fishing....got into the camper and put the front area together. This will lift up for storage.....

 

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Gotta test it....

 

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#67 corybrown50

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Posted 15 July 2019 - 03:08 PM

Well.....now to dig into the roof a bit....she definitely need some help.....

 

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I yanked the cabinet down and this is what I have to work with....

 

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First thing first.....let's get the canvas off.....I made some supports for inside to maneuver around.....

 

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And the back

 

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#68 corybrown50

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Posted 15 July 2019 - 03:14 PM

So, I lowered the roof down to the supports, then released the lifting mechanisms and lowered them. They of course were rusted through, I'm surprised they didn't break. Looks like stainless steel replacements are in order there....

 

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Lowering the lifts allowed me to move the canvas in a way that allowed me to the raise the lifting mechanisms and reattach, shift the canvas, remove the mechanism again, and get the canvas all the way off and down. This was definitely needed for my wife to be able to get it cleaned up before reinstalling later. 

 

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#69 corybrown50

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Posted 15 July 2019 - 03:18 PM

So....the front and back are fried....sides are ok enough to keep.....

 

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Started peeling off the roof inside. I find it interesting how the cabinet was attached to the ceiling. sheet metal glued to the bottom of the insulation.....again, surprised it was strong enough to stay..

 

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#70 corybrown50

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Posted 15 July 2019 - 03:30 PM

Well.....sometimes it snows in April......and sometimes it snows in July in Ohio!!

 

Taking all the insulation down was a pain in the bum.....6" putty knife and hammer scraping it all out by hand.....

 

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You know you have a water leak when you drop insulation from the ceiling on your foot and say "OW!!!"

 

I measured a 2"x2" piece....2.45 oz

 

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So......let's do some math.....

 

2x2" = 4sq in

Ceiling is 84"x143"= 12,012 sq in

12,012/4=3,003

3,003x2.45 oz=7,357.35 oz

 

 

7,357.35oz/16oz= 459.834 POUNDS!!!!!

 

There was a it of dry in there, but let's go SUPER CONSERVATIVE and divide that in half.....230 extra pounds of insulation!!!

 

The scraping actually took a long time, one night and one morning, probably 6 hours total, well, it's clean.......

 

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BUT I'M NOT!!!

 

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