78 Fleet Rebuild

[Pac12_afterdark]

Hello, thought I would document my build thread here.

Overall my goals are to 1) fit more flush with my tundra 2) increase the overhang of the cab over 3) renovate the exterior to match newer style FWCs (I hate my campers square corner windows) 4) increase useable space for hunting and fishing expeditions and 5) create a more sustainable and self sufficient electrical system.


I have had this camper for almost 5 years now and just decided to do something new with it.

Here is the before, as well as the year down as it sits, and some pictures of the new siding I picked up. I’ll try and add some CAD files and schematics here as info for what I am looking to accomplish.

I have some fun ideas and I’m looking forward to sharing. Going to basically follow the “Project Flift” thread for structural changes, with a few tweaks. Welder gets here soon and I can start moving a little quicker.

 

[Wandering Sagebrush]

I look forward to seeing the transformation.

 

[goinoregon]

good luck, for any questions, u are in the right place. nice backyard u have.

 

[Pac12_afterdark]

No big updates today, going to try and move the wall back this weekend.

Ok, maybe one update, new toy came!

 

[pvstoy]

Nice! and nice three vertical pano picture of Zion in the background.

 

[Wandering Sagebrush]

Nice! and nice three vertical pano picture of Zion in the background.

…and here I thought I would be the only one to catch that vertical triptych. Good eye, Patrick!

No big updates today, going to try and move the wall back this weekend.

Ok, maybe one update, new toy came!

Have fun with that new toy!

 

[Pac12_afterdark]

Got some time to mock up the camper “pre” and “post” dimension changes.

Then modeled in crude outdoor shower, cargo pass through, hot water heater cover, egress window and back “flip up” style door I want to do.

Overall I am shortening the “body” of the camper about 13 inches, adding 5 inches to the bottom, and widening the area between the wheel wells by about 5 inches. I still want to detail my trucks bed dimension a bit more to see what space I’m leaving on the table, but ran out of time this morning.

The first two screen shots are its current dimensions with the stubby cab over.

 

[Pac12_afterdark]

Got into it today, this camper was in much worse shape than anticipated, just like all good projects! The front end basically fell apart while moving that wall back. At this point I’m thinking I’ll just go with a total rebuild from scratch of the front wall. Ah scope creep.

Floor pack was decimated as well, which is fine- that’s getting redone anyway to match the dimensions of the truck better.

Here are some carnage pictures. I’m very happy with the shape of the camper after all this!

Im going to move the front wall back one more inch, but I’ll do that after I make the new front wall.

 

[Pac12_afterdark]

Looks like 40ft of tubing to rebuild the front. I’ll grab that next week.

 

[pods8]

At this point I’m thinking I’ll just go with a total rebuild from scratch of the front wall.

That is what I ended up doing with the whole camper on mine aside from the main channel, cause I was changing so many dimensions.

Where are you located?

 

[goinoregon]

you might think about putting exterior rivnuts in, to mount various things on the side back. you can just run a ss screw in to plug them if not using. i thought this approach gave a lot of flexibility - and u will know where all the supports are and backing plates, etc.

 

[Vic Harder]

Now that is an excellent idea! I would seal them (of course) and am wondering how you did it?

 

[Pac12_afterdark]

That is what I ended up doing with the whole camper on mine aside from the main channel, cause I was changing so many dimensions.

Where are you located?

I’m out here in Sandy, Utah. It’s a suburb of SLC!

you might think about putting exterior rivnuts in, to mount various things on the side back. you can just run a ss screw in to plug them if not using. i thought this approach gave a lot of flexibility - and u will know where all the supports are and backing plates, etc.

I’m going to have to look into this, love the idea! If you have a thread of pics please post it here!

 

[pods8]

I’m out here in Sandy, Utah. It’s a suburb of SLC!

10-4, didn't know if you were on the front range here in CO, didn't immediately recognize the peaks.

 

[Pac12_afterdark]

No picture updates, but I did some shopping today.

Got my passenger side window -48x22 half slide half crank.

For the drivers side: hot water heater door (this will allow direct access to the diesel heater from the outside ), 18x22 luggage door (again more outside to inside access), an outdoor shower, and a 18x22 slide window.

I saw a cool heat exchanger that scavenges hot air from the diesel heater to heat water, so I’m going to run one of those for the outdoor shower. Don’t plan on using it much, but they are great when you really need them.

I’ll still need to buy the front window and decide what I want to do for the rear flip up door window wise for the rear. But this will keep me busy for a while.

 

[pods8]

I'm assuming you're already aware but if not State Trailer Supply up in Ogden has a ton of supplies. It was impressive when I stopped in there on a trip through.

 

[Pac12_afterdark]

I wasn’t aware of the Ogden location, I have been to the one on Redwood road in slc. Not sure if it’s the same franchise.
That’s great to know as I’m sure I’ll need odds and ends, always prefer a fair price!

 

[pods8]

Looks like the same franchise so I'd imagine more or less the same stuff. lots of odds and ends.

 

[Pac12_afterdark]

Picked up aluminum for the front today, couldn’t find what the original alloy fwc used, so I went with 6063. Less tensioned strength but similar elongation to 6061. Easier to weld, though. I figured since I’m a novice welder I’d give myself a break.

Parts have started showing up, got the outdoor shower and my passenger side window. Getting excited to assemble!

 

[Pac12_afterdark]

Got the tig fired up today, man that’s fun to do! Still need a lot of practice before I start fabricating!