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Jayco Sportster 8ft - Renovation


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#1 Manfred65

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Posted 01 May 2014 - 07:06 PM

Hello,

 

Thanks to everyone who gave me a warning with the 22 year old Jayco on Ebay Germany/Austria.

Sorry Folks, for ignoring you, but American Popup-Camper are very rare in Germany and Europe.

 

 

http://www.wanderthe...ands-off/page-2

 

Picked it up last week and started to strip it down this week.

Renovation will last its time because i am still in work all week long.

 

First we started a clean up inside the camper and the popup-liner. The liner is in an awesome condition: Only one screen behind the overhead cabinet is broken.There is a Waeco-Compressor Fridge ~ 3,9 cuft and a nearly new Flowjet Water-Pump in the galley.

First we removed the rear window. All dry around !

Stripped the rear right side  paneling then and found rot around the popup mechanism and in the corner. We could see it from inside the cab before.But not as bad as expected.

Before removing the left side panel we have to support the roof because the winch that holds the roof in the upper position is fixed through the rear wall. Will be the first important step to remove the winch and rebuilt the floor and the room where it is located. Found a big hole in the side wall, much bigger than needed for winch access and bigger than the cover.

 

These Jayco campers are very well made! The bottom was complety covered with a thin layer of foam insulation and aluminium sheet  and i have to say thank you very much to the guys at Jayco:

They gave me immediate support, e-mailing manuals and structural informations and measure of bottom and roof. Great Service !

 

 

18147890ox.jpg

18147897kb.jpg

18147906au.jpg

18147910wl.jpg
 

 

 


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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

 


#2 billharr

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Posted 01 May 2014 - 07:46 PM

I will be following to see how your camper comes out. Europe always does things a little different and usually better than we do.

 

 

Bill


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#3 Manfred65

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Posted 02 May 2014 - 07:21 PM

Rear right Corner-Detail:

 

18158992mf.jpg

 

Side view w/o Aluminium Panels

 

 

18158994nz.jpg

 

Cabover rot. Wood lath wanted!

 

 

18158997lb.jpg

 

Front right corner outside and inside:

 

 

18158999ye.jpg

18159000wj.jpg
 

At the moment there are no bigger problems than expected. 


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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

 


#4 Manfred65

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Posted 03 May 2014 - 08:42 PM

Striptease is going on:

 

The front left corner and the screws from the jack bracket. More metal than wood in this corner !

 

18171062cs.jpg

18171067dw.jpg

 

Removed heater, fridge and the "central electric"-parts ( 220V-breaker, conv 220-110V, Main switch 110V and Carson Converter 110V-12V

 

18171126rj.jpg

 

After this i have a free view on the popup-winch:

 

18171087sa.jpg

 

The main problem is the structure that must hold against the pulling cables in the pulleys. I have to lower and to support the roof to loosen the cables.


Edited by Manfred65, 03 May 2014 - 09:06 PM.

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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

 


#5 highz

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Posted 04 May 2014 - 12:07 AM

I'll enjoy following your restoration. I admire people with the skills to take on this kind of project.


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#6 Manfred65

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Posted 04 May 2014 - 08:55 AM

@highz : Thank you for the flowers. The skills are not mine. I am only a bus driver with no craftsman background.

               What you need is:

               - a little tooling and room where to work an to store the demounted parts

               - ability to think straight and to thinks "around the corners" if necessary

               - internet research on special skills, sometimes grabbing from other rebuilds

               - the "Best of all wifes" must support you in the idea and also with practical work

               - the courage to start the project......THERE IS NO WAY BACK IF STARTED.....only a lighter


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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

 


#7 ski3pin

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Posted 04 May 2014 - 02:29 PM

<snip>

               - the "Best of all wifes" must support you in the idea and also with practical work

               - the courage to start the project......THERE IS NO WAY BACK IF STARTED.....only a lighter

 

Manfred, great list!

 

I have a friend who was discussing a possible kitchen remodel with his wife. He brought his chainsaw into the house, cut a big hole in a wall, and announced "Now we are committed!" They are still married.

 

Thanks again for sharing your project with us.


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#8 billharr

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Posted 04 May 2014 - 02:44 PM

  1. - a little tooling and room where to work an to store the demounted part
  2. - ability to think straight and to thinks "around the corners" if necessary
  3. - internet research on special skills, sometimes grabbing from other rebuilds
  4. - the "Best of all wifes" must support you in the idea and also with practical work
  5. - the courage to start the project......THERE IS NO WAY BACK IF STARTED.....only a lighter

 

Lots of wisdom in those 5  points. Especially number 4! Your build will be fun to watch and see how it progresses. Great work on tackling the big items first. 

 

 

Bill


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#9 takesiteasy

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Posted 04 May 2014 - 02:51 PM

Yeah, that's a good list of rules to live by...

 

Good luck with your project. It will be fun to follow along.


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#10 Manfred65

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Posted 04 May 2014 - 07:56 PM

Thank you for your emotional support.

 

The manufacturer called this "plywood"   :D

 

18184913xe.jpg

 

Cabover left side:

 

18184908uv.jpg

 

Cabover right side:

 

18184910ji.jpg

 

Rot like expected!

 

I cannot believe how this construction can hold two sleeping persons:

 

18184911su.jpg

 

EDIT:

There is NO strong construction behind this. The complete front + cabover is only supported by the inner wall covering, aluminium outside panels and the contact to the floorboard. All this with small and smaller staples. You see the vertical metall. It´s the popup mechanism. There is the cabin in the rear and the cabover in the front. Behind the metal tube is only wall-cover of max 1/8" plywood fixed with staples!

 

Checked the Cabover Construction again:

The ply you can see between the frame is 1/2" ply running from the side window to the front corner of the cabover  ~ 90 inches x 10 inches. Very well covered from the inside and exact work outside so i´ve gone wrong with my first analysis


Edited by Manfred65, 08 May 2014 - 08:02 PM.

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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

 





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