Jump to content


Photo

Jayco Sportster 8

jayco sportster

  • Please log in to reply
19 replies to this topic

#11 flon3y

flon3y

    Member

  • Members
  • PipPip
  • 12 posts
  • LocationBellingham, Washington

Posted 09 June 2020 - 08:39 PM

Even with the new wood there was still significant sagging of the cabover, especially when loaded. Before re-attaching the aluminum skin we also installed strapping between the main body and cabover section to really cement things in place. I am pleased to report that the front end is VERY solid now, I would recommend this modification to anyone who has the upper aluminum trim off of the lower body. Below are pictures from one side though this was installed on both. 

 

The steel strapping came from our local hardware store and is impressively strong at about 1/8" thick. The strapping had to be notched to clear the roof lift and I secured it in place using flat head SS phillips screws that recessed perfectly into the perforations. I did pre-drill the screw holes so that the camper framing did not split due to the large diameter hardware.

 

klonOVf.jpg

 

9FDFAvI.jpg

 

DXjZ3jL.jpg


  • 0

#12 flon3y

flon3y

    Member

  • Members
  • PipPip
  • 12 posts
  • LocationBellingham, Washington

Posted 09 June 2020 - 08:58 PM

With the cab over damage dealt with the next area of concern was the camper jack locations and tie downs. Both jack mounts/tie down locations on the drivers side must have sustained water damage at some point and as a result these brackets both had some wiggle in them which was highly concerning. To deal with this we decided to remove the existing mounts and convert to a four-corner jacking system which should provide significantly more stability when not on the truck. 

 

While removing the jack mounts more rot was found in the rear drivers side corner underneath the camper lift crank. We decided to remove the kitchen (which had slight water damage itself) to get to the area and inspect it. In the end a new patch of plywood was spliced into the camper to replace this area.

 

1rYy2fP.jpg

 

wV9lQuz.jpg

 

AEXSnIh.jpg

 

zPezwSc.jpg?1

 

pZrZnS9.jpg


Edited by flon3y, 09 June 2020 - 09:01 PM.

  • 0

#13 flon3y

flon3y

    Member

  • Members
  • PipPip
  • 12 posts
  • LocationBellingham, Washington

Posted 09 June 2020 - 09:04 PM

As shown in the previous photos we also removed all of the inlets/outlets to re-seal them and/or replace them. We also painted the lower section on both sides with primer to seal the wood which will eventually get painted brown to be more subtle. We also painted the passenger side though the wood on that part was in very good shape and required no replacement. A fresh coat of paint sure goes a long ways.

 

d3lVHOr.jpg

 

PvXpJUE.jpg

 

7enJB1W.jpg


  • 0

#14 flon3y

flon3y

    Member

  • Members
  • PipPip
  • 12 posts
  • LocationBellingham, Washington

Posted 09 June 2020 - 09:09 PM

After much testing and deliberation I have come to the conclusion that the refrigerator is currently in-operable as is. The faulty part is the gas valve (pictured) which no longer allows LP to pass through at all. I searched high and low for a replacement part but decided in the end to scrap the fridge and replace it with a newer/larger unit instead of spending more time on it. A full kitchen remodel is now in process!

 

CbwlZuB.jpg

 

 

WNcsHwU.jpg

 

9aTL7Fg.jpg

 

 

xiwLary.jpg


Edited by flon3y, 09 June 2020 - 09:10 PM.

  • 0

#15 flon3y

flon3y

    Member

  • Members
  • PipPip
  • 12 posts
  • LocationBellingham, Washington

Posted 09 June 2020 - 09:15 PM

Upon removing the kitchen I also found a frayed lift cable and opened up eye bolt, those will definitely need some attention. It isn't clear to me how the cable could even fray but I guess 30 years of service will do that. It also looked like someone had attempted to do a partial repair to the system in the past and turned the cables into a crisscrossed mess. At least it will be fixed.

 

WCoaRe3.jpg

 

y2Cmpeo.jpg

 

lm9RLjx.jpg


  • 0

#16 corybrown50

corybrown50

    Senior Member

  • Registered (Tapatalk)
  • 182 posts
  • LocationCincinnati, OH

Posted 09 June 2020 - 09:16 PM

I'm glad to see another one getting back on the road!!

 

I know the work is already done, but I would caution about "splicing" wood for the cabover. This area is cantilevered with the weight getting distributed throughout the rest of the camper when you are up there. 

 

Looks like another total rebuild. I'm very happy that someone is taking the full roof off to rebuild properly. Definitely looking forward to the final product, as well as the journey of another adventurous person digging into a Jayco...


  • 1

#17 corybrown50

corybrown50

    Senior Member

  • Registered (Tapatalk)
  • 182 posts
  • LocationCincinnati, OH

Posted 09 June 2020 - 09:18 PM

Upon removing the kitchen I also found a frayed lift cable and opened up eye bolt, those will definitely need some attention. It isn't clear to me how the cable could even fray but I guess 30 years of service will do that. It also looked like someone had attempted to do a partial repair to the system in the past and turned the cables into a crisscrossed mess. At least it will be fixed.

 

WCoaRe3.jpg

 

y2Cmpeo.jpg

 

lm9RLjx.jpg

 

WOW!! That is definitely scary looking! Great catch!!


  • 0

#18 corybrown50

corybrown50

    Senior Member

  • Registered (Tapatalk)
  • 182 posts
  • LocationCincinnati, OH

Posted 10 July 2020 - 01:14 AM

Any follow up my friend?

Edited by corybrown50, 10 July 2020 - 01:14 AM.

  • 0

#19 HoppyToGoWandering

HoppyToGoWandering

    Member

  • Members
  • PipPip
  • 20 posts

Posted 07 April 2021 - 07:02 PM

I just found your forum and am now following. I have just acquired a Sportster 7 and am going to do similar restoration. Looking forward to following your progress


  • 0

#20 Manfred65

Manfred65

    Senior Member

  • Members
  • 230 posts
  • Locationnear Augsburg, Bavaria, Germany

Posted 09 April 2021 - 06:06 PM

Welcome to the Jayco-Sportster family!

 

After tearing it apart and the rebuild without setting it on fire you will love it like we do!


  • 0

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

 






Also tagged with one or more of these keywords: jayco, sportster

0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users