197 replies to this topic

[ski3pin]

You are doing great with this project, looks great! Thanks for keeping up the posts.

[Manfred65]

Today the rear insulation was covered by some "recycling material". The lines show where to find massive wood if it is necessary to find it while attaching the outside Aluminium panels.

 

Who can find the mistake ?

 

 

Yes, i forgot the wiring for the original rear lamp. But this is no big deal...

 

The Lady signed her piece of art:

 

 

Prepared the new fresh water tank:

 

 

Now it is visible how much water is in it w/o electronics.

 

The wiring to the electric winch and fridge is already prepared now. I consider to prepare the solar wiring in the cabinets.

I don´t know if we are able to repair the roof this fall but i think it is good to have all the wiring to the roof ready to connect.

[Manfred65]

Now all the installations are nearly completed:
Electric roof winch is connected, waiting for the first test. 220V is going to be finished this weekend. Battery, Charger and Furnace are ready. Hope to install the stove the next days.
To finish the 220V, Fresh water inlet and grey water outlet we started installing the sidewall panels today.



 

 

I love the small details so we are now able to open our beer "in style"

Edited by Manfred65, 26 August 2014 - 10:40 PM.

[Bad Habit]

Now that's a good Sarsaparilla :-)

[Manfred65]

..yes it´s good but it has to wait...there will be a time to drink....

now it is time to work:

 

There was a carson converter in this jayco

 

 

 

To remove it left a hole in the galley so i decided to recycle the cover:

 

 

Fresh painted, a covered 220V-Outlet on the left and a combined main breaker/ residual current operated circuit breaker on the right side.   ( Sorry, i don´t know if this is the correct translation).

 

The first window and the fridge grille are fixed and, as a fake: exhaust from 3-way-fridge and furnace to cover the holes in the panels.You remeber there is a compressor fridge + furnace in the rear seat.

 

 

Edited by Manfred65, 27 August 2014 - 09:23 PM.

[ski3pin]

A fun project to watch, thanks!

[Manfred65]

While i was working on our trucks Herculiner-Bedliner, Viola had some progress on the camper:

 

She installed the Fresh-Water-Inlet

 

 

and the frame of the lower fridge access

 

I consider if we will need this additional vent for the compressor fridge. Otherwise it will create a small outside storage or we close it with Styrodur-Insulation inside the door.

 

The Power-Inlet is now converted to a grey-water-outlet, placed in the hole of the former City-Water-Inlet (not needed in Europe).

The Diameter fit perfectly!

 

 

In the first Pic you can see some holes in the aluminium panels. They are remaining from the Jack Brackets and some "wild" additional screws from the last owners. The smaller holes along the sidewall are from Aluminiumplates which were there when we bought the camper. 

 

 

Most of the holes will be covered by some Aluminium-L-Profiles we will bond there. I think this is the best solution:

To ship original Panels ( yes, they are available at Jayco ) is far to expensive and also new Panels made of aluminium or 

fibreglass are too expensive for the budget we planned at the beginning.

And we like the original design very much !

 

I bought a special Air-tool an Air-Nibbler called in Germany to cut the aluminium panels to shape. Low price and easy to work with.

This is a great tool for cutting holes (exact: it stamps the metal, so there are no sharp cutting edges) in thin metal or fibreglass ! 

 

[Manfred65]

The result of nighttime working. I finished the bedliner at 11.30 P.M. yesterday

 

 

 

+ front view of the truck


 

[Manfred65]

Today we first covered the insulation at the cabover. The HDF-wood-panels are bonded and sealed with Terostat MS 939 a special "body glue" for cars, trucks an buses. Nearly the complete repair is made with this glue. It is available in black, grey and white.

Similar to the famous Sikaflex-products.

 

 

Step by step it starts looking like a camper:

 

Edited by Manfred65, 30 August 2014 - 10:44 PM.

[Manfred65]

Today i started with a small but important repair: 

The right side guide of the ice compartments door in the fridge was broken. I fixed it with 1/2" part of an plastic cable channel

 

 

The next door was the one from the propane compartment: 

We installed the frame 180° reverse to the original. Now it opens on the left side. No wind pressure is able to open it now.

The gill plate is necessary because we must have 100 cm² vent for the propane compartment.

 

 

The Aluminium covering is 90% my wife´s job. She did it all from cleaning to the final fixing!  Sometimes it sounds through our workshop:

" I did it darling!"  She loves our Jayco!