OK, I decided to start a new thread and this could just turn into a continued build thread depending on how this all goes.
I posted a bit ago about cracked welds in my frame that I discovered due to door misalignment and what I thought was pretty significant twisting during jacking and lowering of the camper. thread: https://www.wanderth...jackingloading/
I reached out to FWC and they recommended against bracketing the frame connections and suggested welding the inside and outside wherever possible of the frame. They also said that all of the rectangular door frames cracked so that's why they went to the curved top...until just typing that, I hadn't considered retrofitting a rounded top door, but at this point, maybe it's not the worst idea I've had.
Since then a lot has happened:
1. I realized that the front wall had been repaired with brackets and rivets in the past
2. I disassembled the rear wall of the camper down to the bare frame as well as a portion of the side walls to be able to get at the corner where the back wall ties in to the side walls to be able to add reinforcing welds to the inside of the frame connections from corner to corner.
3. I searched high and low for someone willing to do the welding and was surprised at how difficult it was to find anyone. I could only find 2 people willing to do the job and they didn't provide the reassurance i felt I needed so what did I do????......
4. I bought a Tig welder, cause if an entire welding industry doesn't want to touch this thing then why would I think I couldn't do it myself and produce professional results??? haha let's see
4a. I watched lots of videos on tig welding and about 15 years ago i mig welded two halves of a car together to make one care that i was comfortable with my family members driving on the freeway. So maybe I'm not crazy....or maybe I am
4b. I just found out through a friend that he knows someone who tig welds
5. Welder arrived today, and I kinda wanna be really cocky and start practicing welding aluminum cans together, but I bought some practice stock too.
6. I'll also be building a platform out of 2x1" rectangular tubing since my camper requires a booster chair and some extra support on the end hanging out the back of the truck. Wondering if I should incorporate a ski drawer or table stowaway under there, but 2" ain't much
So buckle up and enjoy this thread to be and go read the other thread linked above for some more background if you care to.
1. A couple questions I still have is, should I replace the wall insulation with higher R-Value stuff? Can I do that after the back skin goes on or should it really be taped to the frame rails?
2. Anything I should do while the back wall is completely open and accessible before buttoning it back up? (backup cam, top brake light, steps to get to the roof, wiring for solar or vent fan, etc...)
3. oh and anybody in the southern california area wanna come over and just weld it for me so I don't destroy my camper and stand a chance of going camping sometime soon? (<-mostly...well partly kidding)
4. I was thinking about lopping off the taillights that the Ranger II and saving a couple pounds, but now I'm thinking of incorporating an outside storage box in that area where the camper overhangs the rear of the truck bed...thoughts?