2007 FWC Hawk Remodel

scuba6388

Member
Joined
Jul 15, 2024
Messages
16
Location
Fraser, CO
I've done a few camper builds and remodels now, but never posted the details or progress on one. I figured this would be fun, even though the remodel is almost complete. I did a Promaster van build in 2014, remodeled a Total Composites hardsided camper, and now I'm finishing a full gut and remodel of my 2007 FWC Hawk.

I started out looking for a lower price shell model that needed some TLC. Found this unit for $9,000, which I figured would give me some good room to work with without putting more money into it than I'll ever get back out. Honestly for the condition I probably should have negotiated harder once I got to Arizona.

The camper had good bones, but was a little rough. Canvas is in good shape. Roof was dented up and needed paint. Lots of dents, and the roof wasn't really the new one piece roof as advertised. Interior had the laminated plywood which was all peeling and had been beat up and scratched up by a dog. No sink or fridge, old junk battery, and it was still running the original heater. The batwing awning bag was ripped and someone had clearly damaged the awing as it had bent up arms and brackets.
 

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I look forward to seeing more of your build. With respect to not having the one piece roof, I see that as a positive. My Grandby had the oil canning roof, which made sleeping when it was windy very difficult.
 
My wife and I like to be able to take extended trips and work from the camper. We also had two dogs that *mostly* get along. Important considerations for use were modern electronics, fridge, stove, furnace, sink, a dinette, and maximum floor space we can get with this layout. We also wanted to add more storage. Fitting two mountain bikes without taking the front wheels off is a plus for when we're travelling on salty/winter roads. We decided we didn't need the entire fold-out sofa, but still wanted some room to lounge.

We sketched up this layout:
 

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Having done a van and hardsided camper build we know what we like as far as appliances and such.

Sink setup will be a nice big sink, tall faucet, and simple and easy to winterize jerry can system. We love the jerry can system as almost anyone will let you fill your cans. Two 6 gallon jugs will fit under the sink. One for fresh water and one for grey water. Will use a simple Sure-Flo 12v on-demand pump that works with the faucet to detect pressure and turns on when you open the faucet. The jerry can system allows you to easily dump grey water farther away in the woods, in an RV dump station, or just at home. I typically use a simple RV drain trap to eliminate any smells coming up the drain. With the fresh water it's easy to remove and fill and you can always bring more cans to swap out if we're going somewhere without refills. To maximize space, we went with a flush mount sink and integrated cutting board for a flat surface when not in use.

We'll go with a propane stove as I don't want to waste power on an induction or something like that. I like a plumbed in propane stove as I see the grenade style propane or smaller butane canisters as wasteful and a disposal issue. A larger dual burner stove with fold down top and electronic ignition again maximizes counter space and keeps things clean and simple.

Underneath the stove I can fit a propane furnace. I've had really good luck and 0 issues with Propex furnaces in the past, so we decided to go this route again. It's a full furnace with fully vented combustion, which means it helps dry out the inside, rather than contributing moisture and it's safe to run when we're fully closed up. This unit is pretty quiet for a furnace and comes with a digital thermostat that goes down to 32*.

I've used an ARB cooler style fridge in the past and loved it, but due to the space, we decided to go with at standard front-opening fridge. Decided to gamble on a Bodega cheap chinese fridge. For the price I can buy three to one dometic fridge. We'll see how it does, but so far so good. At this point I don't think there's any reason to go with a 3-way fridge. We'll stick with a 12v, as I like to build electrical systems without an inverter.

For the electrical system, I decided to go with the LiFeBlue 150 AH self-heated lithium. I really like the life blue batteries because of the battery management system. These are safe to charge directly from alternator, whereas most will require a DC-DC converter for proper chargin. Being self-heated we won't have to worry about not being able to charge at low temps, and the batteries have a bluetooth based charge status. The phone app allows you to see actual amperage charge and discharge, % state of charge, voltage, and actual amps. In the past I've had to wire in a shunt and pretty expensive battery monitor.

For charging, I've always liked a simple 12v system with no inverter, since it's more efficient and I can find 12v power supplies for almost anything including our laptops. I've also recently started adding a simple 120v charger and DC converter. This setup makes it super easy to plug in at the house to maintain batteries, plug in at a campground, etc and is worth the $150 or so to have the charger, and pass-through 120v option. I like the Boondocker or PowerMax converters and can get by with a 30 amp charger. I'll use a 120v RV receptacle on the outside, which I wire into two 120v boxes. One outlet stays on the inside of the battery compartment and I plug the DC converter into that (or can be hardwired in). A second outlet will face outside the cabinet and allow us to plug in 120v appliances when we're hooked up to shore power. The cool thing about the converter is that it will charge the batteries but also power all of the 12v needs while on shore power as well.

Solar will be a 200 watt flexible panel and MPPT charge controller from Renogy. I like the flexible panels and I will just use adhesive to stick it to the roof. Less wind drag, no need for a rack and brackets, and snow and ice will not build up under it like a traditional raised hard panel. Theoretically a flat panel will be a bit less efficient as it cannot dissipate heat as well, but I haven't notice much of a practical difference.

Finally, I'll rip out the 7-pin trailer-hitch wiring charging and put in an actual dedicated circuit for alternator charging. My truck has a heavy duty alternator and I have not had any issues with over-working or burning out an alternator in the past. Based on the distance, expected charge amperage, and allowable voltage loss, I'll go with 4AWG and try to keep the wire run as short as possible. Anderson makes some plugs that are rated up to 150 amps and will allow disconnecting the circuit when removing the camper. I used a simple 150 amp solenoid wired into a circuit that is hot when the ignition is on. This automatically disconnects the house battery from the truck when turned off, but allows charging when on. Just for fun, I'll wire the solenoid circuit to one of the upfitter switches in the truck. This will also allow me to manually turn off the alternator charging if I want for some reason.

I'll post some pictures shortly with all of the components of this system and a general wiring diagram I drew up when planning.
 
Sounds like a really good plan!

The only suggestion I would make is to look at the Truma heaters if you are starting from scratch. They are hard to source as they don't sell direct to consumers in the US, but they are far nicer than other options. They are variable speed, when you first switch them on they will be similar to a propex in noise and heat, but once up to temperature they throttle back to 1/3 power which is far quieter than the on/off cycling of the propex or dometic/attwood. This is one of my biggest annoyances with winter camping - I am a light sleeper and the heater cycling wakes me up.

I am considering buying a grey market Truma Combi in Australia and replacing the dometic furnace and water heater with a single quiet unit.
 
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I installed a Propex in my Escape 5.0. It was in a cabinet near the floor under the fridge. I loved it and could hardly hear it. If you were outside you could definitely hear it but not inside. Maybe in a pop up it might be noticeable but no more than the Truma in my Hallmark camper. If you can figure out how to vent it in a pop up I vote for Propex.
 
Here are some pictures of the truck and picking up the camper.
 

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Ripping damaged cabinets and paneling out
 

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Down to the studs. Fixing bad wiring as I go.
 

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Somehow I got no photos of adding insulation. We added 1" poly iso to all surfaces including walls, floor, and under the bed. Photos show progress on paneling and starting to build cabinets.
 

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Got some new wheels and tires on the truck. Went with 35" tires on 17" wheels to fill the wheel wells a bit and provide a softer ride.
 

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One of our first trips with working sink, fridge, stove, and Maxxair fan. No cabinet doors on yet, but making progress on adding angle aluminum trim, solar, flooring, etc. At this point we've also rebuilt the bed slider to accommodate narrower walls due to added insulation and smaller folding bench to fit with new kitchen.
 

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Your build mindset on features sounds very aligned with mine. I look forward to seeing your progress cause it always help refine ideas.
 
I like the look of that cooktop! Is it a domestic d-21? Looks like it would come close to being a drop-in upgrade to the original fwc installation.
 
I like the look of that cooktop! Is it a domestic d-21? Looks like it would come close to being a drop-in upgrade to the original fwc installation.
Yep, it's the d-21. It's been great so far. I can't comment on drop-in replacement since my camper was a shell to begin with.
 
We're mid winter here in the mountains with plenty of snow, so I haven't gotten a whole lot of good pictures lately. I hope to post some more soon with the completed build.

One of the last things I'm looking at doing is adding the Rocky Mounts VanTrack rail system off the back of the camper. I really wish I would have had some plates welded into the camper frame when I had it torn apart. I am a little unsure about the use of rivnuts for mounting a bike rack system on the back. I'd love any feedback and experience from people on this.

Here is the system on my previous camper. I absolutely loved not having to run a hitch rack and the VanTrack with Lolo bar mount system was a lot less weight and really convenient. The van tracks can also accept ski racks in the winter.
 

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Got some new wheels and tires on the truck. Went with 35" tires on 17" wheels to fill the wheel wells a bit and provide a softer ride.
Just from the pictures, it looks like your clearance between the truck cab and the camper overhang is pretty small. It could just be the angle of the camera, though. Make sure you have enough clearance to account for the most extreme relative motion between the truck and camper and for flexing/twisting of the truck. I think most people would recommend at least 2-3 inches clearance on a Hawk/F250 rig, but I don’t have direct experience with that combination myself.
 
Just from the pictures, it looks like your clearance between the truck cab and the camper overhang is pretty small. It could just be the angle of the camera, though. Make sure you have enough clearance to account for the most extreme relative motion between the truck and camper and for flexing/twisting of the truck. I think most people would recommend at least 2-3 inches clearance on a Hawk/F250 rig, but I don’t have direct experience with that combination myself.
Yeah, It's the camera angle. There is about 1" above the two flat antennae (satellite?). The cab has just over 2". I started with a stall mat only and that wasn't thick enough, so I went to a custom built 2x4 frame where the 2x4's sit flat giving me an 1.5" extra height.
 
I tested my rig for flex, driving one wheel up on a ramp that was on the sidewalk with the rest of the truck on the lower road. Good foot or more in the air on one side. The truck flexes, sure.... but the closest point is at the top/middle of the cab roof and as the truck flexes it bends towards the outside edges where there is WAY more clearance than in the middle. I guess it depends on how much your cab roof slopes away from the centre. Based on my observations, 1" is plenty.

Now what I have not been able to test, is how much the camper would dive down in the event of heavy braking or a big wallow in the road at high speed. That could cause contact too.
 
Yeah, It's the camera angle. There is about 1" above the two flat antennae (satellite?). The cab has just over 2". I started with a stall mat only and that wasn't thick enough, so I went to a custom built 2x4 frame where the 2x4's sit flat giving me an 1.5" extra height.
Do you know the measurement from your truck bed floor itself to the cab over in your setup that provides that clearance? It'll be a good sanity check for the dimension I used for my build.
 

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