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Jayco Sportster 8ft - Renovation


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#11 Manfred65

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Posted 06 May 2014 - 07:50 PM

Only office day today  !

 

doing some research on materials an how to fix one problem after the other.....

 

I phoned a bavarian manufacturer of very strong expedition camper cabins. He works with a special type of plywood called "Siebdruckplatte" translated screen printing plate. Pics says more:

 

 

18206643fb.jpeg

 

 

http://www.adventure...ikab/index.html

 

These plates are available in the perfect size  ~ 8ft x 4ft  ( 250cm x 125 cm ) they are very stable and nearly waterproof.

The ply layers are bonded with phenolic resin

They are used for floors in Big Trucks and trailers and on livestock trailers.

 

I can work with thinner material, save weight + add stability. Only use double on the places where the pulleys of the roof lift are located. I think this is the perfect material for use on the bottom part of a truckcamper. 

#1: Reliability: Form follows function.

 

Rustikab uses 3/4" for Expedition Cabins on  4x4  7,5 ton trucks  and  3/8"  for use on Slide in Campers for Pickup-Trucks.

One difference in my plans is it to use Standard - L-shape-Aluminium profiles not the special Profiles used in these professional constructions.

Glue this together with Terostat MS939 + short screws. This will protect me from most "wild" neighbours on european campgrounds.   :D


Edited by Manfred65, 06 May 2014 - 07:53 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

 


#12 Manfred65

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Posted 08 May 2014 - 08:04 PM

Edited post #10 now.

 

We plan to replace the 1/2" side support of the cabover by the same boards like i showed above. But same size than original.


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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

 


#13 Manfred65

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Posted 10 May 2014 - 10:35 PM

There was not so much time this week but today work was going on:

 

Removing lots of screws and staples! I think these camper builders are world champion with the staplegun !

 

Every time you think: "Well lets remove this board, it´s all free!"  there is a staple somewhere you never thought there can be one !

 

Removed the front right corner:

 

18247125ve.jpg

 

also the front wall:

 

18247128ou.jpg

 

Floor on the right side already removed:

 

 

18247126et.jpg

18247127ra.jpg

 

Next steps:  Rust protection on the Lift-system and changing parts of the frame on the right side, replace the front corner and then the rear right corner. Step by step to get no problems with the structure of the camper.

 

Today we realised that this camper has a double floor with a few inches of insulation between the floor boards.


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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

 


#14 Manfred65

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Posted 11 May 2014 - 07:53 PM

No quiet sunday in Bavaria:

 

Repaired some structural problems today. The right side corners are replaced and also the horizontal frame. We cut the vertikal frame to shape to give place for stronger horizontal frame. It´s use ful to install some useful staff later. We will fit Airline tracks like in transport vans in this part of the frame to carry some stuff like a small table, bottle opener   :D   or only for a cord to hang something away from the ground.

 

 

18258567ai.jpg

18258569do.jpg

 

Front right corner:

 

18258572kj.jpg

 

Rear and total:

 

18258573hm.jpg

 

You can see some dark parts on the inside sheeting. There is only 1/16" of ply remaining to hold the inside decor. To glue a sheet of plywood outside to support these parts is a job for the evenings.
 


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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

 


#15 takesiteasy

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Posted 11 May 2014 - 09:05 PM

This is quite a project! You are making good progress. Thanks for posting the pictures. It is fun to follow along.


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#16 ski3pin

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Posted 11 May 2014 - 11:21 PM

Looks like great progress and a good job on your part. Thanks for sharing!


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#17 Manfred65

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Posted 17 May 2014 - 08:18 PM

Back here again:

We had a little progress today. Little because the gods of the tool wanted to annoy me and tucked my tools..... :angry:

We placed an additional Frame brace in Front. Original there was only the front wall. We think it will give more rigidity, thinking about the roof lift.

18312417pm.jpg

The lower wood lath is only for rigidity during our work.

The pulley in the left corner was replaced sometime ( not OEM) but it is already cracked:

18312420vg.jpg

I think i will replace it by a stainless one.

Then we finished the left side frame:

18312418tu.jpg

No better view possible, because the camper sits very close to the wall on the right side.
Tomorrow i hope to finish the left rear corner.

To replace the floor we are planning now with a sandwich of PU-Block-Foam and Plywood with HPL-Cover ( like on countertops )
This cover is very reliable against scratches, salt, water, oil and you can hit it with a hammer ( like shown in the Hallmark-Video ) without any damage. And it is available in thousands of designs.


Edited by Manfred65, 17 May 2014 - 09:03 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

 


#18 Manfred65

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Posted 18 May 2014 - 08:48 PM

Next frame repairs:

 

The rear left corner:

 

18327251fk.jpg

 

The lower part of the entrance frame is missing. That´s work left for the week...

 

Right back side finished as far as possible:

 

18327252kb.jpg

 

If one has never done such a renovation he cannot believe how filigree such a frame is. Cutting one screw or staple at the wrong time and you can see how the forces find their way!   :unsure:     You need to have the "global view" while working on the camper. 

I think it is easier to build a cabin from ground up than to renovate one and have to change essential structural parts.

 

A little rust protection on the roof lift was another job of the day:

 

18327253wd.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

 


#19 Sock Puppet

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Posted 25 May 2014 - 07:29 PM

Amazing project, thanks for sharing!


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#20 Manfred65

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Posted 26 May 2014 - 07:59 AM

Because our car needed some TLC this weekend there was not the big progress:

 

Reinforced the locations of the tiedowns:

 

18404129bg.jpg

 

Replaced the right floor over the bedrails:

 

 

18404116ti.jpg

 

18404126ku.jpg

 

18404120hs.jpg

 

...and removed the bottom wall of the right side.


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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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