Design and build a camper trailer - novice

[debruiser]

After recently purchasing an AWESOME D90, then trying to fit anything in the back other than your lunch I've realised that I'm going to want a camper trailer of some form. I could just tow the box trailer and throw everything in there! BUT that's a bit simple and things will get dusty and it's not much of an improvement over using the old ute. So the idea came to me that I could make a slide on for the box trailer. You know the basic set up - slide out kitchen, slide out fridge, solar panel, battery, water tank, storage for cooking stuff and food with the roof top tent on top. Easy. But the empty trailer is close on 400kgs, it's on 16 falcon tyres and it's got a wider track than the D90. So it'd be HEAVY by the time I stick on a slide on and add camping gear and water/fuel/beer.

I like the look of the Xtrail XMT/A1 trailer as well as the AT adventure trailer. Very similar ideas and simple! Both are too short for my tent! I have a Maggiolina Airtop which measures 2100x1450x300. yes I could just stick it on the D90 but the idea is to move it to the trailer so I can unhook and go for a drive without packing up camp!

So here is my question:

HELP! no wait that's a statement.... :P

Ok really what i'm looking for is experience and knowledge, drawings, photos, ideas, suppliers of cool stuff, anything I can't think of because I havn't done this before.

Would it be better (yes I know some of you will cringe here) to start with an old army trailer - maybe a No5? take the box off and use that for the chassis? I don't want fancy pretty boy independent susspension, I just want a solid axle with a leaf under it - simple reliable effective! I also want to match the wheels to the Defender - so I can use the spare wherever in an emergency.

Key points for me are:

- Tent must remain below car roof line
- Water tank
- battery
- sink
- uses coleman cooker that I already have
- simple
- dustproof
- reasonably light - under 750kg loaded would be good (was thinking it'd need brakes for safety anyway)
- tows well
- fridge
- awning
- tough - don't want it to fall apart, and yes I realise that this is a contradiction to the light statement.
- Solar panel - if I can afford one.

I'm certain that I've forgotten plenty of stuff but that's why I'm throwing this out there - any ideas would be appreciated.

Thanks

[weeds]

What's your budget??

I built one using a 130 tub.....my RTT was also a little long but it seems to fit OK. I had an axle build so that I could bolt on defender stubs and hubs....plenty of spares if need, it will soon have defender calipers

[weeds]

http://www.aulro.com/afvb/projects-tutorials/125879-hcpu-tub-trailer.html

[debruiser]

Budget... yes... well.... $0. :wasntme: Seriously though. This is going to be a project, bits at a time sort of thing so I can gradually buy bits as I need them/can afford them. I would prefer it to take longer to build because I spend a little more on quality rather than quick and crap.

[debruiser]

http://www.aulro.com/afvb/projects-tutorials/125879-hcpu-tub-trailer.html

Thanks for that link weeds, i've already had a squiz at your build! I've been looking around at the site a bit but it's sometimes hard to find just what you want.

I don't realy want to go down the "bolt a tray on a chassis" track... I feel it'd lead to the whole hinged lid bit and I"m not keen on that because once you put up the tent you can't get in the trailer. I'd prefer side access.

One thought that had crossed my mind was to use a series tub and cut it up to make it open wherever I want and really only LOOK like a series tub in the end.... maybe that train of thought needs more work....

could use a roof for the lid too!

[Mick_Marsh]

Here's some ideas.

If you were starting with an old Army trailer, I wouldn't go No5 or Workshop. No brakes.
You're probably going to load up the trailer. It will easily go over 750kg.
I would expect the Haulmarks have brakes and possibly the Cooks. I know the Tracks do.
Track have a nice civvy one available but don't look at the price.
https://www.aulro.com/afvb/

I wanted something similar so I bought an ex-RAAF Track. All I did was put some drawers in it and bolted a camper top on it.
https://www.aulro.com/afvb/
https://www.aulro.com/afvb/

The camper top was bigger than I wanted but it was the only one I could find with a 1.2m drop.

[debruiser]

so after a few discussions with people about design etc here is a sketch-up of my current thoughts. because of my lack of cad style drawing skills(also lack of really caring about having every detail drawn) there are a few surfaces and framework missing - I have an idea of what framework I will use....
https://www.aulro.com/afvb/images/imported/2013/06/459.jpg (http://s1295.photobucket.com/user/debruiser/media/TrailerDrawingFrontright_zps6b4e07b1.jpg.html)

So what you see there is the front right corner. To try to make sense of my drawing I shall try to explain.... remember the front and side sheeting is missing...
- front has a slide out draw for fridge/esky (can't afford a fridge yet but going to make it compatible)
- right side front door (swings forward) is a battery compartment - battery on floor with fuses, dual battery system (charge from car), inverter and solar power plug/controller (when I can afford it) + other electrical bits

moving towar rear is a storage compartment (door opens up)
rear is another storage compartment (door upwards) between 2 storage compartments is a couple of rungs - ladder style to access the tent! saves carrying the ladder for the tent (crossed fingers)

https://www.aulro.com/afvb/images/imported/2013/06/460.jpg (http://s1295.photobucket.com/user/debruiser/media/TrailerDrawingRearleft_zps799c545b.jpg.html)

This is the kitchen side.... roll out awning
The lift up legs will be on the other side too, just too lazy to draw themon.

so at the front there are shelves for the cooker
middle is shelves/draws not sure yet....
rear is a built in sink on the "bench" that is actually the side of the box that folds down. in the cavity where the sink folds into there will also be power for the tent (light) plus external light and 240V (when i get money for the inverter) plus light switches for fixed lights all around the trailer.
the rear of the box has the lift up door (again the sheeting is missing from the rear) this area will be general storage for long /heavy things.

Under the kitchen there will be a water tank. Under the right hand side storage areas there will be a diesel tank with transfer pump. Weight distribution has been a bit of a concern for me... so I think I will lean towards wasting a little space to get the tanks over the axle rather than having too much weight at the front of the trailer.

I was thinking as far a solar goes I will just get some of those roll out panels and when I stop plug them in then lay them ontop of the tent before opening.

Should mention that I'm going to have the awning on "telescopic" mounts - 25mm RHS main supports in the box will have a 20mm RHS inserted that can slide up and down with pins to lock at the height I want.

Can anyone think of any problems with my design? suggestions?

wow this must be my longest post ever.... :angel:

[debruiser]

no comments. I'll take that as a complement [bigwhistle]

[gavinwibrow]

no comments. I'll take that as a complement [bigwhistle]
Looking good. I think Ranga's utetop version (currently still for sale?) is one of the simplest and best designs/concepts I have ever seen. If I have a wee win in Lotto, I'll be over in a flash.

[MR LR]

no comments. I'll take that as a complement [bigwhistle]
Looks like it's lower than the Defender? Realistically you want it at the same height (chassis height) or even higher if you intend it to follow where the 90 will go. Looks good though :)

Also think about departure angles and all that if you want to take it off road, do you?

Cheers
Will

[pop058]

If you use an ex-mil workshop trailer or a No.5, then although your wheel PCD will be the same as your 90, IIRC the track is different.

I have the traditional fold out type camper tent mounted on a ex-mil workshop trailer. You have to be fairly careful when packing as the is limited space and access under the bed base.

You Sketch Up drawing looks great.

[bigcarle]

i am a novice but i bought a Castle Camper and it is under 750k (no brakes on it) and it has all that you listed and i got mine for around $8k in semi off road configuration (4WD wheels/ tyres and heavier axle) all based on a Nathan Trailer made in Brisbane

[Brad110]

Here's some ideas.

If you were starting with an old Army trailer, I wouldn't go No5 or Workshop. No brakes.
You're probably going to load up the trailer. It will easily go over 750kg.
I would expect the Haulmarks have brakes and possibly the Cooks. I know the Tracks do.
Track have a nice civvy one available but don't look at the price.
https://www.aulro.com/afvb/

I wanted something similar so I bought an ex-RAAF Track. All I did was put some drawers in it and bolted a camper top on it.
https://www.aulro.com/afvb/
https://www.aulro.com/afvb/

The camper top was bigger than I wanted but it was the only one I could find with a 1.2m drop.
Mick

What's the brand of tent?

I have a camper on 130 tub and have a height of 1250- 1300.

[debruiser]

Looks like it's lower than the Defender? Realistically you want it at the same height (chassis height) or even higher if you intend it to follow where the 90 will go. Looks good though :)

Also think about departure angles and all that if you want to take it off road, do you?

Cheers
Will

Yea the trailer is sitting on falcon tyres :( it was custom built YEARS ago for Dad's little tractor to go in.... but the tractor is gone and he doesn't use the trailer much so I'm trying to inherit it ;) it's one tough little trailer.... I'm thinking that I will try to save up some more cash and then put some 4x4 tyres under it....

[debruiser]

i am a novice but i bought a Castle Camper and it is under 750k (no brakes on it) and it has all that you listed and i got mine for around $8k in semi off road configuration (4WD wheels/ tyres and heavier axle) all based on a Nathan Trailer made in Brisbane

Thanks for the idea. Just had a quick look and they look ok, but I don't want the whole palace style tent thing.... I have a Airtop tent already that I just can't bring myself to get rid of....

Maggiolina | Airtop | (http://www.autohomeaustralia.com.au/productinfo.php?category=1&product=4)

Plus the whole $8k bit is a bit beyond me ATM. At least building the box I can buy bits in dribs and drabs.

[debruiser]

Ok just ordered a couple of poly tanks - 1 for water and 1 for diesel! plus sender units and gauges to suit. Will pick them up Wed next week.

Had another thought about the construction of the box! maybe I should forget having a 13x13 RHS frame sheeted in thin ali and just get thicker Ali sheeting - weld that up. I know that Ali is harder to weld and that I'd need to purchase the ali welding kit for my mig as well as a bottle of gas but what would be cheaper? Has anyone priced this sort of thing before?

[Homestar]

I would think a steel frame with Ali skin would be cheaper, but all ali construction would be lighter. You will need good fabrication skills to make the whole lot from ali. Also, while I'm not 100% sure, I think the steel frame would stand up to vibration better long term.

[debruiser]

I would think a steel frame with Ali skin would be cheaper, but all ali construction would be lighter. You will need good fabrication skills to make the whole lot from ali. Also, while I'm not 100% sure, I think the steel frame would stand up to vibration better long term.

yea that's pretty much sums up my thoughts too, but I thought it'd be interesting to put it out there and see what others think.

Also while we are on the topic of ali.... if I want thin sheeting what grade of ali will I be able to get cheap? and what grade is appropriate for this application?

[Mick_Marsh]

Mick

What's the brand of tent?

I have a camper on 130 tub and have a height of 1250- 1300.
Trekmaster 9 Offroad.
Dingo Campers - Camper Trailer Tents / Tops For Sale To Fit Trailers & Utes (http://www.dingocampers.com.au/kits.htm)

[debruiser]

Sourced a fuel tank and water tank, 80L each and very very close to the dimensions I was hoping for. Will pick them up Wed next week!

Was drawing up my wiring diagram from the trailer and was thinking about dust (while driving). Would it be worth installing a simple pressurising system? Ie. small fan pressurising the box with a dust filter in the line, much like what some caravans use OR maybe more of a 4x4 snorkel set up.....

The other question would be what is the simplest way to set up the electrical side of that? I will have a charge system from the car (restricted to about 8amps or so) should I run a relay off that charge line so that when there is charge coming from the car the fan runs? That should give me essentially an "ignition" switch? no.... (will be running a redarc duel battery setup between car and trailer)

[Kevin B]

Here's some ideas.

If you were starting with an old Army trailer, I wouldn't go No5 or Workshop. No brakes.
You're probably going to load up the trailer. It will easily go over 750kg.
I would expect the Haulmarks have brakes and possibly the Cooks. I know the Tracks do.
Track have a nice civvy one available but don't look at the price.
http://www.aulro.com/afvb/attachment.php?attachmentid=61314&stc=1&d=1370246080

I wanted something similar so I bought an ex-RAAF Track. All I did was put some drawers in it and bolted a camper top on it.
http://www.aulro.com/afvb/attachment.php?attachmentid=61317&stc=1&d=1370246477
http://www.aulro.com/afvb/attachment.php?attachmentid=61318&stc=1&d=1370246551

The camper top was bigger than I wanted but it was the only one I could find with a 1.2m drop.

Thats Awesome, where did you get the tent top, I also need a 1.2m drop

Kevin

[debruiser]

Trekmaster 9 Offroad.
Dingo Campers - Camper Trailer Tents / Tops For Sale To Fit Trailers & Utes (http://www.dingocampers.com.au/kits.htm)

I think this is what you were looking for

[debruiser]

OK so I've made a few little tweeks from the plans I've posted.

Got the fuel and water tanks last week, and have ordered:
- Fuel pump
- water pump
- sink
- air filter (for pressurised air system)
- air duct (for pressurised air system)
- steel
- ali sheeting
- lots of cutting discs

Also have laying around:
- Blower unit from a Series 3 LR for pressurised air system)
- Hinges
- other random stuff that I will need.....

Steel and ali is turning up next week, so next weekend will be the real start date.

Still chasing some series land rover bonnet stays.... see my wanted post if you have some to offer.

[86mud]

Have you looked at the myswag.org forum? The built up section has some great ideas...try this one:

Custom off-road pop top camper (http://www.myswag.org/index.php'topic=31018.0)

[debruiser]

Have you looked at the myswag.org forum? The built up section has some great ideas...try this one:

Custom off-road pop top camper (http://www.myswag.org/index.php'topic=31018.0)

I can only hope that I fluke my camper to look that good! wow.

[Datt]

I'm looking forward to seeing your progress.

I'm in the process of sketching up a design to get quoted on. I wish I had the ability to weld it up myself to save a few bucks but we'll see what the quote comes back at.

Here's some pics of the design so far, a long way from finalised.
https://www.aulro.com/afvb/images/imported/2013/07/1042.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1043.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1044.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1045.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1046.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1047.jpg

Matt.

[roverrescue]

Matt,
Nice drawings.
Two points if I may.
-If you are starting from a blank page reconsider the independent swing arms... pm if you want a full explanation or just search on some of my previous rants ;) I guess if you plan on buying pre-manufcatured swing arms then carry on.
-Second, change up the rear mud flap design. Either finish the folded sheet at the level of the gusset and continue it with rubber or alternatively put in a second gusste back to your corner posts.

Regards,
Steve

[debruiser]

I'm looking forward to seeing your progress.

I'm in the process of sketching up a design to get quoted on. I wish I had the ability to weld it up myself to save a few bucks but we'll see what the quote comes back at.

Here's some pics of the design so far, a long way from finalised.
https://www.aulro.com/afvb/images/imported/2013/07/1042.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1043.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1044.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1045.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1046.jpg
https://www.aulro.com/afvb/images/imported/2013/07/1047.jpg

Matt.

Matt, wish I could "sketch up" like that! nice. Why does everyone want independent suspension on a single axle trailer??????? I can sort of see the point on a tandem.... but just looks too overcomplicated to me.

What sort of tent are you planning on using? a typical trailer tent or some type of roof top tent? I'm guessing your planning the old tailgate kitchen setup.

[Datt]

Matt,
Nice drawings.
Two points if I may.
-If you are starting from a blank page reconsider the independent swing arms... pm if you want a full explanation or just search on some of my previous rants ;) I guess if you plan on buying pre-manufcatured swing arms then carry on.
-Second, change up the rear mud flap design. Either finish the folded sheet at the level of the gusset and continue it with rubber or alternatively put in a second gusste back to your corner posts.

Regards,
Steve

Thanks for the comments Steve.

I was planning on buying the swing arms premanufactured from Vehicle Components. I've searched your posts in relation to this am very interested in exploring other designs though in particular the triangulated 4 link. Is it compatible with air springs or a combo of coil and load leveling bags?

I will change the rear of the mud flap to finsh with the gusset and continue with rubber. Good call.


Matt, wish I could "sketch up" like that! nice. Why does everyone want independent suspension on a single axle trailer??????? I can sort of see the point on a tandem.... but just looks too overcomplicated to me.

What sort of tent are you planning on using? a typical trailer tent or some type of roof top tent? I'm guessing your planning the old tailgate kitchen setup.

Thanks Debruiser for the comment.

This vid got me first thinking about independant Suspension Comparison - YouTube

I was searching after seeing video of lots of trailers up the Cape almost bouncing themselves over onto their roof. I'd like to see an unbiased comparison between designs.

I guess I'm chasing a compromise of on road handling for light to heavy loads, a degree of suppleness for bouncy off road work, reliability, durability, ease of acces to parts if gone remote and lastly cost effective. All are considerations and the end product will have to be a compromise because I doubt one product will do all.

I'd like to be able to use my trailer as a box trailer for the majority of the time then slide a chuck wagon style box on for camping kitted ready to go. Maybe a rooftop tent later down the track for when the kids get a bit older.

My idea for the kitchen is to be side mounted (passenger side) for easy access while on the road when you pull up for lunch or a late breakfast after you're already on the road. Possibly gulwing door to give some cover for quick stops as well as an awning for when set up at camp.

Lots of ideas in my head and examples out there to investigate. The end product will suit me though and not neccesarily others.

Matt.

[debruiser]

Thanks Debruiser for the comment.

This vid got me first thinking about independant Suspension Comparison - YouTube

I was searching after seeing video of lots of trailers up the Cape almost bouncing themselves over onto their roof. I'd like to see an unbiased comparison between designs.

I guess I'm chasing a compromise of on road handling for light to heavy loads, a degree of suppleness for bouncy off road work, reliability, durability, ease of acces to parts if gone remote and lastly cost effective. All are considerations and the end product will have to be a compromise because I doubt one product will do all.

I'd like to be able to use my trailer as a box trailer for the majority of the time then slide a chuck wagon style box on for camping kitted ready to go. Maybe a rooftop tent later down the track for when the kids get a bit older.

My idea for the kitchen is to be side mounted (passenger side) for easy access while on the road when you pull up for lunch or a late breakfast after you're already on the road. Possibly gulwing door to give some cover for quick stops as well as an awning for when set up at camp.

Lots of ideas in my head and examples out there to investigate. The end product will suit me though and not neccesarily others.

Matt.[/QUOTE]

That video seems a bit bias to me.... or that is a rubbish leaf spring trailer... Although I can agree that coils would ride better to some degree. I'd like to see that it's worth the over-complication of a TRAILER.

I'm going with the same sort of plan as you. Box trailer with a slide on! Kitchen in the left side only I'm making my kitchen fold down, so I get a big old bench. for Shade I'm planning on an awning of some kind, havn't finalised that yet though. Already have a roof top tent for on top!

My biggest problem with the trailer I'm using is that it's only on Falcon tyres :( so they are a bit small and leave the trailer sitting reasonably low for offroad use. The only fallback the it has is that it's custom built and tough enough to skull drag across some surfaces.... The plan is to eventually move the mud gaurds up and put 7.5" tyres on it

[roverrescue]

Matt,
Obviosuly that video is marketing and with marketing you tell the story you want to tell how you want to tell it. And make sure you dont show the pitfalls of your product.
All that video tells me is that dodgy, short trailer leaf springs are dodgy (but I knew that).
And that even a completely terrible damper arrangement (as seen on the VC arms) is still better than no damper at all.

With a triangulated four link you can run coils or air.
Shoddy Pics of the last four link trailer on coils are here:
http://www.aulro.com/afvb/trailers-vans-campers/131001-offroad-boat-trailer.html

The current build I am doing will use Firestone rolling sleeves with different link geometry
I will try to document this build here:
http://www.aulro.com/afvb/trailers-vans-campers/178035-chassis-build-box-trailer.html

Obviously if you are getting this thing made, supplying the fabricator with components that bolt/ weld on will save on labour as opposed to the ginning around that I get up to!

Happy to pm yarn anytime

Steve

[debruiser]

Well the steel turned up yesterday, as well as a bunch of other stuff like the water pump and fuel pump. I've started on the basic frame but it's a lot of cutting and welding so not a lot has been done. :( I will have to get some photos of the progress and post them later on.

[debruiser]

So I've spent a couple of afternoons cutting and welding up the beginnings of the frame. At the end of each session I have been giving any welded bits a quick prime to stop any rust. Here are a couple of progress photos.

Front Right
http://i1295.photobucket.com/albums/b640/debruiser/Day1FrontLeft_zps827326a0.jpg (http://s1295.photobucket.com/user/debruiser/media/Day1FrontLeft_zps827326a0.jpg.html)

Front Left
http://i1295.photobucket.com/albums/b640/debruiser/Day1FrontRight_zps08816ac4.jpg (http://s1295.photobucket.com/user/debruiser/media/Day1FrontRight_zps08816ac4.jpg.html)

Rear
http://i1295.photobucket.com/albums/b640/debruiser/Day1Rear_zpsfbaa2b3a.jpg (http://s1295.photobucket.com/user/debruiser/media/Day1Rear_zpsfbaa2b3a.jpg.html)

I know it doesn't look much at the moment but hopefully it comes out nice. O and yes I'm using a gasless mig :( can't afford to build this thing and get a gas bottle too, plus i dont know that I'd know what to do with the bottle anyway :(

The first afternoon I started on it my grinder died! :censored: So I had to go buy a new one. Got a 125mm Hitachi Professional model, seems pretty good.

So there's still lots to go. more photos as I get it done.

[Homestar]

Got a 125mm Hitachi Professional model, seems pretty good.


I've got the exact same one I have and it is a ripper. I've had mine for years and use it almost every weekend and have abused it heavily and it's still going strong.:)

I've cut up huge chunks of steel with it and have had it so hot I can't pick it up, but it still goes like a beauty.

[debruiser]

Day 2 down. Lots of cutting and welding today. It's gotta be the biggest welding job I've ever done. :o

Front
http://i1295.photobucket.com/albums/b640/debruiser/Day2Front_zpseed834b5.jpg (http://s1295.photobucket.com/user/debruiser/media/Day2Front_zpseed834b5.jpg.html)

Rear Right
https://www.aulro.com/afvb/images/imported/2013/07/555.jpg (http://s1295.photobucket.com/user/debruiser/media/Day2Rearright_zps43c0d611.jpg.html)

Rear Left
http://i1295.photobucket.com/albums/b640/debruiser/Day2Rearleft_zps63f25948.jpg (http://s1295.photobucket.com/user/debruiser/media/Day2Rearleft_zps63f25948.jpg.html)

I still can't decide how to make the shelves! Some inspiration is needed. Should I use 3/8 marine ply or try to fold up ali ones? I don't have a sheet metal folder so I have to just fake it with a lump of 2inch angle iron. What would you do?

O and for those of you thinking dam that looks heavy; it's all light gauge steel so I can still lift it on my own (bit awkward though).

[debruiser]

The mrs is already thinking about going camping at christmas time. We sort of thought that heading south away from the heat and rain might be a good idea. Is there any suggestions for camping spots? Would be good if we could do a little 4x4ing/fishing/kayaking as well.

[goanna_shire]

Hi Debriuser,

We have had those hitachi grinders in the workshop for years and they have copped the worst abuse I've ever seen. They still come back for more:D. I'm keen to see this trailer of yours turn out. It looks great so far.

Cheers,
Brian

[debruiser]

Hi Debriuser,

We have had those hitachi grinders in the workshop for years and they have copped the worst abuse I've ever seen. They still come back for more:D. I'm keen to see this trailer of yours turn out. It looks great so far.

Cheers,
Brian


Brian

I've only heard good things about hitachi grinders, lets hope that I'm not the first one to have problems. I'm a bit of a hitachi fan to tell you the truth, I've got their 4" belt sander - animal of a thing! so much fun! Plus I have an 18V set of toys, they are soooo much fun too. And pretty good tools as well. In fact the 18V drill I have (with hammer function) will actually turn a bigger bit better than my 240V 500W Makita drill!!!! WTF!

The slide-on. well, it looks good to you cause you can't see up close :wasntme: na really I'm actually reasonably happy with it so far. There is SO SO much work to go on it though, and plus lots of money to spend too, havn't got all the parts I need. I'm using old series 3 land rover hinges that I cut "flat" (because they are angled and wouldn't work in the setup I'm making) had to order bolts to mount those today, hopefully they will be here in time to start fitting them when I need them. I'm also using the 'demister' from a Series 3 LR too! it's going to be my pressurised air system - got a 4" pod filter to attach and going to wire it off the car ignition so it's plug and play.

The biggest concern for me as far as purchases go at the moment is latches, originally I thought that I could use series 3 LR burstproof door latches and modify the latch to work in my situation, (I have a couple of them laying around) this would add to my retro LR look :cool: but I'm thinking that they will be too hard to modify. So was thinking of using a drop T-handle w/lock, what worries me is fitting them and price. They are pretty steep and I can't afford to get a whole set that wont work for me. Maybe i should just buy these locally so I can play with them before purchasing.

[debruiser]

well i ordered a tigerz11 awning the other night, 2.5m x 2.5m with mozzie net. Seemed like a bargain. (they are having a sale!)

Got a few more parts show up in the mail.

Other work has been slow. I've made up mounting brackets for the water and fuel pumps as well as a bracket for the pressurized air. Also had to custom fab a couple of 4" air flanges to suit. Started making door frames as well. Drilled the frame for mounting most of the hinges, but have to buy some more steel to make up a couple of brackets to mount the rest of the hinges to the body.

So there isn't much to see in a photo - hence no photos today. Maybe tomorrow....
Hopefully during the week I will get the extra steel and continue fiddling.

[debruiser]

So here are some photos fo the progress... doesn't look much. :(

Some hinges
https://www.aulro.com/afvb/images/imported/2013/07/152.jpg (http://s1295.photobucket.com/user/debruiser/media/Day5bits1_zpsc58577a1.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/07/153.jpg (http://s1295.photobucket.com/user/debruiser/media/Day5Bits3_zps5d1db011.jpg.html)
Yes that is a 4" pod filter! and yes it will be working backwards.... but I figure it wont matter too much it's only a trailer.

https://www.aulro.com/afvb/images/imported/2013/07/154.jpg (http://s1295.photobucket.com/user/debruiser/media/Day5bits2_zps549fe0fe.jpg.html)
Dont know what happened to the paint in that one... going to have to fix that up

https://www.aulro.com/afvb/images/imported/2013/07/155.jpg (http://s1295.photobucket.com/user/debruiser/media/Day5rear_zpsd6ee10e5.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/07/156.jpg (http://s1295.photobucket.com/user/debruiser/media/Day5Left_zps5bde6105.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/07/157.jpg (http://s1295.photobucket.com/user/debruiser/media/Day5Right_zps5f7c238a.jpg.html)

just ordered a set of runners to make the fridge slide. It's just going to roll out from the front. Also ordered door locks/latches. Ran out of money now so gotta just play with what I have.

[Cracka]

Nice job Debruiser. I'm watching your build with interest. I have a nice off road gal 6 x 4 that I wouldn't mind doing something similar to, so I can put the roof top tent onto when I don't plan on towing the boat

I have been looking at expedition portal, Ih8mud, compact camping concepts and other sites for ideas. Good to see you getting stuck in.

Mick

[Homestar]

Looking good. I like the positive pressure fan idea. Will be interested to see how that works. I used to work at the Open cut Coal mines in the Latrobe Valley and the main switch room in the Loy Yank bunker is right in the middle of the dustiest part of the building and is pressurised and did a very good job of keeping things clean. It still got some dust in, but only a tiny fraction of what would otherwise have got in there.

[debruiser]

Looking good. I like the positive pressure fan idea. Will be interested to see how that works. I used to work at the Open cut Coal mines in the Latrobe Valley and the main switch room in the Loy Yank bunker is right in the middle of the dustiest part of the building and is pressurised and did a very good job of keeping things clean. It still got some dust in, but only a tiny fraction of what would otherwise have got in there.

That was what I was hoping for.... stole the idea from caravaners. :angel:

[debruiser]

Draw slide turned up for the fridge yesterday, so I spent half the day fitting those and making up the draw slide. It's looking like it will work pretty good.

Was thinking about power usage with a fridge and solar was my favourite idea for keeping things going. 1st I thought i'd use a flexible solar panel, and throw it over the airtop before lifting the airtop. But they are super expensive compared to solid units. So then thought maybe just use the fold out units that sit beside the trailer, but they leave stuff on the ground where you can trip on it - and it's more stuff to set up! YUCK! So what I'd love to do is have a slide system for a solid panel that slides under the RTT, but because of the finished hight of the slide on a standard draw slide would leave the panel at a great height for me to gouge eyes out on the corners. So has anyone made a sliding/tilting arrangement that would move the panel up out of the way? I thought about a drop fridge slide sort of setup but that would still leave a bit of draw runner sticking out at eye level. Any ideas, hints, suggestions, pictures would be great!

Thanks ahead! :D

[debruiser]

Telescopic awning mounting.... Down - transport height
https://www.aulro.com/afvb/images/imported/2013/08/1499.jpg (http://s1295.photobucket.com/user/debruiser/media/Day7Awningmount_zps24494b79.jpg.html)

UP
https://www.aulro.com/afvb/images/imported/2013/08/1500.jpg (http://s1295.photobucket.com/user/debruiser/media/Day7AwningMountup_zpsf379ea0a.jpg.html)

Awning installed - temporarily for testing purposes
https://www.aulro.com/afvb/images/imported/2013/08/1501.jpg (http://s1295.photobucket.com/user/debruiser/media/Day7Awningout_zps739f879f.jpg.html)

Fridge/esky slide nearly finished
https://www.aulro.com/afvb/images/imported/2013/08/1502.jpg (http://s1295.photobucket.com/user/debruiser/media/Day7Fronteskyin_zpsd0321df1.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/08/1503.jpg (http://s1295.photobucket.com/user/debruiser/media/Day7FrontwEsky2_zps402d886a.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/08/1504.jpg (http://s1295.photobucket.com/user/debruiser/media/Day7Frontright_zps4f88e2f3.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/08/1505.jpg (http://s1295.photobucket.com/user/debruiser/media/Day7slide_zps422acacb.jpg.html)

Just another pic.
https://www.aulro.com/afvb/images/imported/2013/08/1506.jpg (http://s1295.photobucket.com/user/debruiser/media/Day7Side_zps13725063.jpg.html)

Have decided that I will put a sliding solar panel in. Just have to save up for it and the bits and pieces I will need. Also have to engineer the slide/tilt system.

Gave up work today because I ran out of steel... well need some different steel.

Might cut out the floor tomorrow ready for installation, see if I can get someone to help me out.

[Cracka]

Looking good Debruiser.......

How are you going to deal with the cladding of the box. Straight down the sides to the bottom rail. If so, what will you do about the water/rain that will run down the side between it and the trailer wall and sit underneath. Or have you got a cunning plan such as stepping it out over the capping of the trailer walls.

Not a criticism, just wondering for my own ideas thats all.

Mick

[debruiser]

Looking good Debruiser.......

How are you going to deal with the cladding of the box. Straight down the sides to the bottom rail. If so, what will you do about the water/rain that will run down the side between it and the trailer wall and sit underneath. Or have you got a cunning plan such as stepping it out over the capping of the trailer walls.

Not a criticism, just wondering for my own ideas thats all.

Mick

umm.. yes.... hadn't thought about that! it's a good point because the trailer will hold water! gee... dont you just hate when you think you have everything pretty much under control and you've missed a biggy! :angel:

I was going to sheet straight down to the bottom of the box with plain old ali. (0.6mm) I will have to sleep on that one. Thanks Mick :)

[Cracka]

Thats ok mate, we've all been there I'm sure. Its one of the issues I had been thinking about and couldn't see if you had thought about it.

Just a thought, if you made the frame work above the trailer walls just outside the outer edge, you could sheet to below the top edge of the wall. And then have a sealing strip, be it rubber or neoprene on the top edge of the trailer wall for the frame work to drop down onto then hopefully making it waterproof.

Or if you didn't want to adjust your frame, maybe make like a z shaped flashing to go down the frame, across the trailer wall and then down a little way. Your outer sheeting could then just go down over this. You could still have a seal under here as well.

Just a couple of ideas.

Mick

[debruiser]

Thats ok mate, we've all been there I'm sure. Its one of the issues I had been thinking about and couldn't see if you had thought about it.

Just a thought, if you made the frame work above the trailer walls just outside the outer edge, you could sheet to below the top edge of the wall. And then have a sealing strip, be it rubber or neoprene on the top edge of the trailer wall for the frame work to drop down onto then hopefully making it waterproof.

Or if you didn't want to adjust your frame, maybe make like a z shaped flashing to go down the frame, across the trailer wall and then down a little way. Your outer sheeting could then just go down over this. You could still have a seal under here as well.

Just a couple of ideas.

Mick

Thanks for the ideas Mick. I should have made it hang on the sides of the trailer as you suggested, it would have bought me some extra room inside as a bonus. I was trying to keep it narrow because the trailer is already wider than the defender so didn't want to make too much air drag... Would have also let me make the fridge slide ~75mm lower. I've had to put the fridge on top of the runners instead of between; I ran out of room in there, my original calculations were obviously out by 10mms or so :(

Maybe a piece of flashing is a good idea. OR I saw a friend or a friend who had a tray back camper (on a 4ton truck) his storage doors on the outside, he'd used a piece of 4x4 flare - you know the generic stuff that TJM/ARB/supercheap sell. He didn't put the wire in, just the rubber, and it worked like a gutter sort of thing to run the water away from the open door. Maybe something like that would be a good alternative, that way it's a bit flexible and shouldn't get damaged loading and unloading. I would have to find a cheaper alternative to the flare stuff though, it's EXPENSIVE and I'd need roughly 7.2meters of it!!!!!! :eek: maybe Ovesco has something.... Let me know if you see something.

[Cracka]

G'ay mate, unfortunately when we do these types of things, I should say, I do these things. I always come up with a better plan when half way through or finished.

Thats probably whey I never get my projects started, I over think them :confused:

If I think of anything I'll let you know.

Mick

[debruiser]

G'ay mate, unfortunately when we do these types of things, I should say, I do these things. I always come up with a better plan when half way through or finished.

Thats probably whey I never get my projects started, I over think them :confused:

If I think of anything I'll let you know.

Mick

Don't you just hate it when your finished a job, stand back and then think, "dam that was the hard way to do it" or "I should have done that; bugger it, too hard to change now" :D

[Cracka]

G'day mate how is it going?

Check this out that I just found, it's pretty neat.

Welcome (http://www.turtlebacktrailers.com/Turtleback_Trailers/Welcome.html)

Mick

[debruiser]

G'day mate how is it going?

Check this out that I just found, it's pretty neat.

Welcome (http://www.turtlebacktrailers.com/Turtleback_Trailers/Welcome.html)

Mick

Mick, nice link! If I had of found that in Oz, I may have just purchased it! Looks like a pretty good layout and good features. Unfortunately it looks like a cool room with a tent on top :( maybe they will bring out coloured versions!

I will take some photos this afternoon after I finish working on the trailer for the weekend. I'll post them up.

[Cracka]

Yes your'e right about the coolroom look, I don't mind it though, it may stop prying eyes and hands :mad:.

I found it on ExPo, the builder/designer replied and said that one was just the prototype and was asking for peoples advice on changes required.

Look forward to your updates, have a good day.

[debruiser]

Front - got most of the floor in. lots of pop rivets in there....

https://www.aulro.com/afvb/images/imported/2013/08/1066.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk3Front_zps17baed79.jpg.html)

Fridge draw - has the door attached to the draw so it all opens at once.
https://www.aulro.com/afvb/images/imported/2013/08/1067.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk3fridgedraw_zpsdec90f87.jpg.html)

Electrical board painted up ready for install. What do you think of the colour? It's Ocean Blue hammertone. I was thinking of painting the whole thing that colour.
https://www.aulro.com/afvb/images/imported/2013/08/1068.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk3ElectBoard_zps63df96e9.jpg.html)

Found these in Masters today, (it's their "Grand Opening" today in Mackay). Thought that they would go really nicely for the 'kitchen' area on the camper.
https://www.aulro.com/afvb/images/imported/2013/08/1069.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk3Lights_zps750b730d.jpg.html)

[Cracka]

Looking good mate, I don't mind that blue. What colour is your truck?

Good score with the lights. They aren't bad those Masters store, I had a look for the first time on wednesday while I was in Canberra having some work done to "Ivy".

[debruiser]

My D90 is keswick green w/ white roof.... I was going to colour match the trailer, but the MRS wasn't too enthusiastic about it

[Cracka]

I thought I had seen a post somewhere else that it was Keswick, nice. That's what I was going to say, colour match it. You could even lash out and give the trailer a fresh coat of white, then it would look like an ordinary box trailer when in that configuration :cool:

You would only need to paint the "box" keswick as your RTT, I'm assuming here, being white would look like the white roof to match the 90.

[debruiser]

I thought I had seen a post somewhere else that it was Keswick, nice. That's what I was going to say, colour match it. You could even lash out and give the trailer a fresh coat of white, then it would look like an ordinary box trailer when in that configuration :cool:

You would only need to paint the "box" keswick as your RTT, I'm assuming here, being white would look like the white roof to match the 90.

Yes that was my thoughts as well! The box trailer will go to a white/off white I would think. But I was thinking the same wiht the camper - make it colour matched and then wiht the tent on top it'd look nice..... will have to think about it some more.

[pop058]

Yes that was my thoughts as well! The box trailer will go to a white/off white I would think. But I was thinking the same wiht the camper - make it colour matched and then wiht the tent on top it'd look nice..... will have to think about it some more.

Just something to consider if you go with white is the fact that chips and scratches in your paint can "bleed" and leave rust trails down your paint work.

[debruiser]

Just something to consider if you go with white is the fact that chips and scratches in your paint can "bleed" and leave rust trails down your paint work.

yea good point. The trailer is already an off-white colour... so might stick with something similar.

[Flipper]

Looking great so far Debruiser,
Just a thought on sealing the gap in from the side walls to trailer.
If you get some 8mm sail track, rivet a length around the top of the trailer and another length to the walls of your camper, then have your local upholstery shop sew up some marine hooding with rope ends to run around all this.
The tailgate is an issue, but this can be solved with bungies so you un-hook them first before dropping the rear gate.

Second thoughts, sail track around the walls of the camper and it would be easy to either lace on the fabric to the trailer rails or use bungies or press studs all around to the trailer.
Doing it this way will make it dust and water proof and will look professional.
Attached is a diagram of 2 methods I am64344 thinking of.

[debruiser]

Looking great so far Debruiser,
Just a thought on sealing the gap in from the side walls to trailer.
If you get some 8mm sail track, rivet a length around the top of the trailer and another length to the walls of your camper, then have your local upholstery shop sew up some marine hooding with rope ends to run around all this.
The tailgate is an issue, but this can be solved with bungies so you un-hook them first before dropping the rear gate.

Second thoughts, sail track around the walls of the camper and it would be easy to either lace on the fabric to the trailer rails or use bungies or press studs all around to the trailer.
Doing it this way will make it dust and water proof and will look professional.
Attached is a diagram of 2 methods I am64344 thinking of.


hmmmm.... not a bad thought at all! I might just steal the 2nd thought.

[debruiser]

Here is some excitement for your day. On second thoughts if my posts are your most exciting thing for a day then probably you need to get out more :p

Couple of new pics... finally started on the kitchen shelves/draws. It's not screwed into place yet. Going to get it all fitting then pull it all out to paint the frame. Then it'll all go back in and get a final painting.

https://www.aulro.com/afvb/images/imported/2013/08/615.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk4Kitchenstarted_zps8468b5ac.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/08/616.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk4Kitchenstarted2_zps9edba75d.jpg.html)

Was thinking of painting the ply/wood with paint rather than varnishing. My experiences with marine grade varnish havn't been the best.

At last it's starting to look like something... not just a bunch of random RHS' welded into a cube.

[Cracka]

Good job mate......ahhhhh sawdust.......

I guess no matter what type of coating you use, to some extent it will wear.

[debruiser]

yea sawdust everywhere.... how does it do that!

I would have preferred to go ali kitchen shelfs, bench, draws BUT I can't weld it... A: don't have the gear, B: Not sure that I have the talent. SO marine grade ply plus some timber is the go.

I've got a nice little sink on order that should go very nicely! unfortunately it's not here yet :( hopefully it gets here this week.

Yes I hope any coating I use wears (otherwise I've put in a crap load of work for something that isn't getting used!). I have used marine grade varnish before on outdoor furniture and found it to flake and peal. I dont want that happening to this - it will be far too hard to revarnish and plus I dont want the ply getting wet and chance having it fall apart.

[Cracka]

The flaking varnish on the outdoor furniture might have been due to the UV exposure maybe. At least inside the camper they won't get that.

I see a lot of the Americans use the herculiner type products, you know the anti skid good wearing rubberised stuff for utes/trailers beds. I did see our local auto parts place were now selling the rustoleum brand kits, not sure on the price or how far they would go, but that might be an option for the top working surfaces and then paint/varnish/epoxy resin even, the underside/edges.

[debruiser]

Very excited! Got the sink and faucet turn up in the mail today! YAY! Now I can get stuck into the kitchen and get it all fitted up.

[Homestar]

Very excited! Got the sink and faucet turn up in the mail today! YAY! Now I can get stuck into the kitchen and get it all fitted up.

Faucet - really? Can't we just call them taps over here?:D

[debruiser]

Faucet - really? Can't we just call them taps over here?:D

:Rolling: :Rolling: :Rolling: :Rolling: :Rolling: :Rolling:

But seriously I thought that a tap, was well.... a tap. and the faucet was the 'spout' :)

anyway it's a bit more fancy than I had thought... the 'spout' /tap/faucet is a tap with spout, what I didn't realise is that it has an electric switch on the tap! how fancy is that! Before you say it though, I'm not going to trust it completely, I'm going to have a kill switch on the circuit for the water pump. I've heard of people driving rough roads and having the taps wind themselves on...

[Homestar]

Yep, have a separate isolation switch on the pump, you don't want to turn up to your campsite to find out you have no water for the evening or longer...

[debruiser]

Well, this week has been pretty good. Actually seem to have made some progress - you know the kind that you can see.

Got the kitchen setup finished and screwed in. Got the back section on that. Also go the roof on, and the floor section on the storage area. Plus I got a 1st coat of primer on most of it. O, and got the frame made up for the solar panel.

Pics to prove it.
https://www.aulro.com/afvb/images/imported/2013/09/1681.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk6RearRight_zps9f283482.jpg.html)

I've got 2 draws for the middle section of the narrow area of the shelves.
https://www.aulro.com/afvb/images/imported/2013/09/1682.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk6RearLeft_zps6c4afe0a.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/09/1683.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk6Front_zps2c744df9.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/09/1684.jpg (http://s1295.photobucket.com/user/debruiser/media/Wk6Frontleft_zpse1595a9d.jpg.html)

[debruiser]

ahhh how good does it feel when you feel/look like your getting somewhere with your project! :D:D:D:D:D:D:D

Ok so all the sheeting is on the box now! with primer! Kitchen is ready and holes are cut for air intake, fuel and water fillers.

https://www.aulro.com/afvb/images/imported/2013/09/1257.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk7REarleft_zps1fc86065.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/09/1258.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk7rear_zps0bd29fca.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/09/1259.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk7right_zpsfcce0986.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/09/1260.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk7Frontleft_zps73d3105c.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/09/1261.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk7front_zps9a6550aa.jpg.html)

Here's a couple of door frames with the 1st coat of colour on them.
https://www.aulro.com/afvb/images/imported/2013/09/1262.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk7Doors2_zps168c9ea8.jpg.html)

Just realised that you can't see the door frames much... o well....

Next on the list is paint the inside hammertone silver. Then paint the outside, fit the rear door, sheet all the doors, paint doors, wire, plumb, bolt on solar and tent. Need to also make the lifting legs.

[Cracka]

Looks good debruiser, your'e cracking along now.

[debruiser]

Looks good debruiser, your'e cracking along now.

Thanks Cracka. It felt like it would never end for a while there..... but now that the sheeting is going on it's a different story. Can't wait to get all the fabrication work done so I can move onto wiring and plumbing. Although plumbing is going to be a pain! I know for a fact that the diesel pump has different size fittings on it to the tank and I'm pretty sure that the water is going to have the same issues.

[debruiser]

Been doing battle with paint the last week. I think I'm sorta winning. Inside is hammer finish - metalic silver. Outside is Jasmine Green hammertone. I'm not very happy with the finish on the outside. I really struggled getting the gun to throw it... the compressor is old and I think has lost some of it's perk as well so that wasn't helping.

https://www.aulro.com/afvb/images/imported/2013/09/1006.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk8FrontRight_zps266fc114.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/09/1007.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk8RearLeft_zps331a760d.jpg.html)

[Hoges]

t'rffic job:D following with much interest. However something seems to have happened to photos in previous posts ... they've apparently been moved/deleted from the host. any chance of resurrecting them?

FWIW: The use of a fan to pressurise the camper body is OK providing that you have it pretty well sealed, otherwise the fan can't keep up. It draws the dust in because of the very large vacuum produced behind the camper body. A pair of simple deflectors to redirect airflow around the rear of the camper body ( like they used to have to deflect air across the rear windows of EH Holden station wagons) can help a lot...

[debruiser]

t'rffic job:D following with much interest. However something seems to have happened to photos in previous posts ... they've apparently been moved/deleted from the host. any chance of resurrecting them?

FWIW: The use of a fan to pressurise the camper body is OK providing that you have it pretty well sealed, otherwise the fan can't keep up. It draws the dust in because of the very large vacuum produced behind the camper body. A pair of simple deflectors to redirect airflow around the rear of the camper body ( like they used to have to deflect air across the rear windows of EH Holden station wagons) can help a lot...

Yea I was sorting out my photobucket and apparently the photos don't work. If I get a chance tonight I will see if I can sort it out.

The fan thing... yea I'm hoping that I get a reasonable seal, but wont really know until I get the doors finished. The rest of the box should good, I've used 3 tubes of sicaflex 221 - everywhere that the sheeting touches metal it has sicaflex under it. IF the fan can't keep up I might looking at getting a better one (this one is just a series 3 LR fan and fan box) OR might just jam a better motor on the fan.... see how it goes first.

[debruiser]

Well after a couple more weeks of working part time on the camper here is some progress.

Roof bars to put the tent on. and mount the solar to.
https://www.aulro.com/afvb/images/imported/2013/09/601.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk10RoofRack_zpsa839f15c.jpg.html)

Water and air pump installed
https://www.aulro.com/afvb/images/imported/2013/09/602.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk10Pumps_zpsa29d3860.jpg.html)

a door ready for paint
https://www.aulro.com/afvb/images/imported/2013/09/603.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk10Door_zps9fcdaa29.jpg.html)

Kitchen area fabrication complete. Just got to finish the door and attach:
https://www.aulro.com/afvb/images/imported/2014/09/678.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk10RearLeft_zps407e2bce.jpg.html)

Kitchen door/bench, needs a sink and hinges/locks.
https://www.aulro.com/afvb/images/imported/2013/09/604.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk10kitchenbench_zps04cf9754.jpg.html)

Tomorrow I will be working on the rest of the doors to get them to painting stage.

[debruiser]

Doors are painted! YAY! feels like I'm getting somewhere.

Went shopping for plumbing bits today (as well as a few electrical bits that I need) took ALL morning. It was painful, no1 had what I wanted and noone was very interested in helping, although I did strike one guy who was quiet helpful.

Turns out that Series Land rover fillers are an odd size and that a 70mm fuel hose is hard to bend.... :( SO off to the muffler shop. Got some bits of pipe and spent half the afternoon cutting htem up. Had to make a gadget that went from 70mm to 1.5inch and around a 90degree bend all at once.

On a more positive note I almost the ahve water tank fully plumbed! yay.

[debruiser]

Well after spending a whole morning shopping the other day and some deliveries coming in the past day I think I have all the parts I need! Just a matter of putting them all together now! :D :D :D :D :D :D :D :D :D

[debruiser]

Week 12 - progress, seems that FINALLY this thing is starting to look like a camper. Got all but 1 light wired up over the past week as well as plumbing almost all done. Had to make a crazy crazy pipe to fit the Series 3 filler to the tank... had to go from 70mm pipe round a 90deg bend then reduce to 1.5inch all in the space of a couple hundred mm. It was interesting to say the least, cross your fingers that the tank will fill ok.

Unfortunately I've run out of fasteners at the moment so progress has ground to a halt. Also found out that the Land Rover hinges just wont cut it for the kitchen door, so I've had to get some more stainless strap hinges.

So some pics.
https://www.aulro.com/afvb/images/imported/2013/10/1158.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk12FrontLeftOpen_zps9ef3a813.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/10/1159.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk12FrontRightclosed_zps56b09850.jpg.html)


Have to fix up some of the cable ties in here... the sticky back thingos don't work like it says on the packet.
https://www.aulro.com/afvb/images/imported/2013/10/1160.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk12Rear_zps8a344c53.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/10/1161.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk12RearleftOpen_zps40538d74.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/10/1162.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/wk12Rearleftclosed_zpsc9e629d1.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/10/1163.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk12Roofsetup_zps5afd0811.jpg.html)

[Chops]

Its looking very good DB,
Someone asked before about pics,, just wondering if you've made any progress with them.
I'm keenly interested as I'm about to start rebuilding my unit for the crew cab. Although somewhat smaller, I wanted to keep the weight down, but I suspect shelves and dividers will be easier to do in steel sheeting. In my first experiment/trial, I don't really have anything specific, but am using heavy wood ply.
I was going to do a steel frame with Alloy cladding and shelving etc, but still haven't decided yet.
What have you done about legs for your set up?

[debruiser]

Thanks Chops. I'm starting to think that it will turn out ok, there has been a few times that I was worried that it would look like a backyard job...

Photos.. I can't seem to edit older posts so I can't update the link BUT let me try this:

Camper Trailer Slideshow by debruiser | Photobucket (http://s1295.photobucket.com/user/debruiser/slideshow/Camper%20Trailer)

That should be a slideshow of everything I've uploaded (cross your fingers)

I have made a 20mm RHS frame - some sections (load bearing) are 25mm. with the 40mm 'lifting tubes' all lightweight. I think sheet it with 0.6mm Ali. the floor I used a sheet of 2mm Ali. It does flex but I put some reinforcing under it, that stiffened it up BUT that shouldn't matter too much because it all sits on the trailer floor anyway and the trailer is PLENTY stiff. The steel frame I can lift on my own (i'm not that strong) the ali I could lift on my own if I could get a grip of it... So it's not Toooooo heavy. Although now I don't know if i can lift one end anymore.

The shelfs rest on 20mm RHS and have vertical supports behind. Shelfs, these things were worrying me quiet a bit! Strength vs weight and all that. Mum and Dad had a Hymer motorhome, so I went and had a squiz at that and they (Hymer) have used 3 ply for the whole cupboard set-up. What they have done is use 3 or 4mm ply for the shelf and verticals but they just put a little piece of timbre frame around the shelf and up and down front/back of the verticals. These are quiet strong, the motorhome had done 170000kms or there about from memory and these cupboards were all original equipment and non were broken. I know for a fact that Mum had been transporting canned food on the shelfs across corrugated roads. I figured that it it's good enough for Hymer to do back in the 80's, then it's good enough for me! SO I think I used 6mm ply (my shelfs are much larger than the motorhome) and put the timbre reinforcing where I think I needed it. The shelfs have turned out pretty strong, obviously I haven't road tested it yet though so time will tell.

Lifting legs:
Wow, some thought is going into these. 1st I was just going to use axle stands under the trailer, but too slow, and fiddly. then fixed length legs with plates under, can't lift the box out with them.... So bought 4 x 380kg jockey wheels for $10 each, BARGAIN! No clamps with them though. so the latest plan now is to get some pipe that will sleeve over the jockey wheel upper (after the handle is removed) then extend the centre shaft up to the hight of the pipe and attach a nut/drive device to turn it with either a drill or spanner. I then need to connect it to the camper, which is the tricky part - 32mm RHS slots into the 40mm RHS then a linch pin to secure. I'm currently thinking that I will try to make that fold down against the jockey wheel for transport but it will need to be simple and strong, so I havn't decided how to do that yet. It's a work in progress, and at least if I get the camper done I can just use the axle stands temporary until I get the legs done, that way we can enjoy my hard work and money....

That's gotta be my longest post ever :D

[debruiser]

Yay the slideshow seems to work! :D:D:D:D:D:D

[gavinwibrow]

Don't forget Ranga's just sold version. Although designed for a flat top, rather than a trailer per se, its one of the best thought out and executed lift off versions I've ever seen and could easily be adapted to your needs.

[Cracka]

Looking good debruiser. When we were discussing the water down the side issue some time ago, from memory, too lazy to go back and look:p, you talked about maybe making up a skirt so to speak.

I was driving through Yarrawonga the other day and saw a tray top ute with sides on it, just normal fold up/down type. He had a camper shell fitted to it. about 150 - 200mm above the top of the side was a sail track fitted to the camper with black canvas/vinyl fitted in it, that then went down over the sides and was held down by elastic/bungy cord as per a tonneau cover.

I thought of your build, it looked like a neat solution.

Mick

[debruiser]

Looking good debruiser. When we were discussing the water down the side issue some time ago, from memory, too lazy to go back and look:p, you talked about maybe making up a skirt so to speak.

I was driving through Yarrawonga the other day and saw a tray top ute with sides on it, just normal fold up/down type. He had a camper shell fitted to it. about 150 - 200mm above the top of the side was a sail track fitted to the camper with black canvas/vinyl fitted in it, that then went down over the sides and was held down by elastic/bungy cord as per a tonneau cover.

I thought of your build, it looked like a neat solution.

Mick

Thanks Mick.

That was pretty much what I was thinking about too.... just simple and with flexibility.... But to tell the truth I had forgotten about it, I've just been working at getting the main box done and to a usable state. I keep running into little bits of not so much trouble but just things that need tweeking or are not exactly what I anticipated. For example, the water filler hose has to follow a path that kinks it, so I've had to order those hose spring things to keep it nice. Doors are a PITA to fit... and the hinges I planned on using (cut down defender hinges) wont work because of the door setup. This was much disappointing because I wanted to link a couple of things back to the car, ie, the door hinges, air intake, fuel filler, door props... but it seems to be that hinges wont be one of them.

The current fiddly bit is attaching rubber strips to the bottom of the camper to protect the trailer / camper from damage during transit. Also should deaden some of the noise. Will post a pic when I get it done.

[Chops]

The pics look good DB, thanks for sorting that :D
Looks good and strong, so I don't think you'll have any problems. As with all new things we do, just do some quick check as your going,, more for piece of mind I think over anything. But certainly worthwhile, if a problem starts, you can nail it before it becomes a real show stopper.
Top stuff, I hope mine turns out looking as good as yours dude :D

[Don 130]

A suggestion if I may. Another option with your lifting legs is to cut the wheel off and before replacing it with a flat plate, add an extra length of the same sized ( inside ) tube to extent it to the correct height. That way you don't mess about with extending the winder.
Don.

[debruiser]

Don,
Yes good idea! that would be FAR simpler, I was thinking that the wheels might be handy for when it's in storage. They would allow me to move it around a little maybe. Or do you think that it would be to unstable and the legs would just want to fold up?

[debruiser]

Well it was a pretty good day today. I put the door rubber on the kitchen door, plus did a couple of tidy up bits, then it was tow the trailer into the yard for the first time. Filled the water tank to flush it out, but then found that I had a couple of leaks in the plumbing.... quick fix on that and then onto cleaning. Set up the awning and cut the fly mesh so that the kitchen is accessible.

The Mrs was pretty excited so she was cleaning it all out and putting in non-slip stuff.... then loading kitchen essentials in. Esky and cooker in, ready to go. Tomorrows job is to wire the D90, so that the it will charge the battery while driving (solar panel will not... it's shaded by the tent) there will also be an accessories signal wire to activate the pressurised air system.

As yet I haven't made the lifting legs... they have me perplexed a little. I have some trailer jockey wheels that I'm modifying for the job and I'm troubled with how to make it all compact, strong and simple.

https://www.aulro.com/afvb/images/imported/2013/10/555.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk14Rearright_zpsabb1ed15.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/10/556.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/wk14Fontleft_zps57e54188.jpg.html)

https://www.aulro.com/afvb/images/imported/2013/10/557.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk14FrontLeftawning_zpsd5bccf15.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/11/152.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk14Kitchen_zps823c9254.jpg.html)

https://www.aulro.com/afvb/images/imported/2015/11/151.jpg (http://s1295.photobucket.com/user/debruiser/media/Camper%20Trailer/Wk14kitchenrear_zps8e620a66.jpg.html)

[Chops]

Hey DB, just remember to make your legs out far enough to clear the trailer wheels/guards. ;)
Just weld matching tube (for the trailer side) to the top of the leg, give it a foot to stand on, you can actually buy feet for this type of thing, so get the legs without wheels, unless you want to be able to roll it around, which could be a bonus too.

[gavinwibrow]

Not the best picture for your purposes, but talk to Ranga about his excellent stands.

[debruiser]

Hey DB, just remember to make your legs out far enough to clear the trailer wheels/guards. ;)
Just weld matching tube (for the trailer side) to the top of the leg, give it a foot to stand on, you can actually buy feet for this type of thing, so get the legs without wheels, unless you want to be able to roll it around, which could be a bonus too.

Ahh yea Chops, got the wheel arch width under control ;) The problem with just welding a RHS on the side of the Jockey is that I end up with a great big right angle 'thing' that will take up lots of room! I was hoping to carry them with me camping so that I can use them to stabilize and level as well. SO I was hoping to make the 'insertion tube' fold flat or close to flat against the jockey.

Gainwibrow - I can't open the file... :( Could you repost it without the zip?

[debruiser]

I shoudl have mentioned that the solar panel seems to be working well in that configuration. I didn't put the tent up and so didn't pivot the panel yesterday but I"m going to assume that it wont make a huge difference. I was getting up to 8amps of charge (120W panel).

[debruiser]

Hey DB, just remember to make your legs out far enough to clear the trailer wheels/guards. ;)
Just weld matching tube (for the trailer side) to the top of the leg, give it a foot to stand on, you can actually buy feet for this type of thing, so get the legs without wheels, unless you want to be able to roll it around, which could be a bonus too.

Chops, have you seen feet for sale? can I ask where? OR what do I google to find them? Would "trailer stand foot" work?

[Homestar]

Is this the sort of thing you are looking for? They can be bought off ebay or caravan places.

Google wind down stabiliser legs and there are heaps.

http://www.aulro.com/afvb/attachment.php?attachmentid=67287&d=1382215375

[Homestar]

Or this?

Google trailer jack for this type.

http://www.aulro.com/afvb/attachment.php?attachmentid=67289&d=1382215687

[Chops]

Hey Gav, where'd you find the pic of the wind up unit. I found some a while ago, almost the right height, but way too exxy for my liking.
They can be bought straight from places that make the big ally tool boxes too.

DB, you could make your legs so they have a hinge where it joins the leg, but they'd have to be made to fold "up" making them longer when not in use.

This sort of stuffs always a challenge, trying to keep weight and price down :eek:

[Chops]

One could go "All Electric",,, nice and cheap ehh :eek:

Slide on Camper Legs - HAPPIJAC 4600 Electric kit With Wireless Remote - Quality RV, Caravan and Motorhome Accessories (http://peninsularvs.com.au/store/Slide-on-Camper-Legs/HAPPIJAC-4600-Electric-kit-With-Wireless-Remote/prod_60.html)

[Chops]

Some more options for you DB

camper jacks | Ripperdeals-au.com (http://www.ripperdeals-au.com/index.cgi?query=camper%20jacks)

[debruiser]

Thanks guys, those are the type of thing I want.... BUT the budget has pretty much closed on this project (for now anyway) so think along the lines of $50 to complete..... :( ouch yea I know.

SO i already have the jockey wheels, scored them on sale for $10 each! (got 4 of them)

before I started building I did lots of searching the net to get ideas, and try to source something that was usable. The problem is like those cool electric ones, the price! ($3000 for 4 legs!!! you HAVE TO BE JOKING!) That's my WHOLE budget for the build... well maybe a little under but still.

The other problem I found with those premade legs was that:
a) they are too long, or
B) they are too short.

My trailer is a custom jobbie, made about 15-18yrs ago. Was originally designed to carry a small tractor but that has since gone and now the trailer remains.

I had an appifany this morning. Forget pivots, they are fiddly and weak. I though maybe plug together, so the extension from the camper to the leg plugs into the leg... so it's 2 peices, a little fiddly to build but easy, quick and strong.

Chops I actually thought that you meant that you could get the 'foot' of the leg when you said that you could buy 'feet'. sorry my bad.... :)

[gavinwibrow]

Ahh yea Chops, got the wheel arch width under control ;) The problem with just welding a RHS on the side of the Jockey is that I end up with a great big right angle 'thing' that will take up lots of room! I was hoping to carry them with me camping so that I can use them to stabilize and level as well. SO I was hoping to make the 'insertion tube' fold flat or close to flat against the jockey.

Gainwibrow - I can't open the file... :( Could you repost it without the zip?
Sorry, just a bit too big to post here without zip. PM me your email address and I'll forward it that way.

Or if you prefer, contact Ranga direct on this site - he's in Qld too and would be happy to help/comment.

Cheers Gavin

[Chops]

DB, if you've already got the legs, just lengthen them with a bit of pipe, and you could get a couple (4) square feet, either cut from a steel merchant, or get a length to suit and you cut them. That should keep the price down for you.
These are ones you can get from Camac.
Trail-A-Mate Hydraulic, Replacement Flat Base | Caravan Brackets & Parts | CaravansPlus (http://caravansplus.com.au/catalog/product_info.php?products_id=1092)

I couldn't believe how much those electric legs were. They'd be nice, but there's no way I'd be having them :eek:

[debruiser]

DB, if you've already got the legs, just lengthen them with a bit of pipe, and you could get a couple (4) square feet, either cut from a steel merchant, or get a length to suit and you cut them. That should keep the price down for you.
These are ones you can get from Camac.
Trail-A-Mate Hydraulic, Replacement Flat Base | Caravan Brackets & Parts | CaravansPlus (http://caravansplus.com.au/catalog/product_info.php?products_id=1092)

I couldn't believe how much those electric legs were. They'd be nice, but there's no way I'd be having them :eek:

Chops, I plan to cut the wheel bracket off and slide a tube inside the lower pipe then weld ti there.... do you know if they make 38OD pipe? I ahve to go to metaland and buy some. I can't believe that they want 40bucks for a flat piece of steel. stuff that I'll just get some from somewhere.

I think what i'll do is weld a 40mm rhs to the jockey then take a 32mm rhs slide that into the 40mm RHS in the camper and then use linch pins to connect it all together. If I do it right there should be only minimal slop. That way it's simple, quick to assemble/pull down, strong and packs reasonably small.

[Chops]

If you want cheap steel, try a welding shop and see if they want to get rid of some offcuts.
You could also try for the same thing at a small steel sales shop.

[debruiser]

Got the lifting legs finished... forgot to take a photo. Anyway we went out camping this weekend; Eungella dam. Was pretty good, apart from the wind Friday night, there were storms out near Moranbah that got the wind going most of the night. Left after work on Friday, didn't get away from home till about 4:30, was raining here in Mackay, got further up the Valley and it cleared up but when we got up to Eungella it was super foggy! was driving at about 30km/hr just to see where we were going.

Anyway, the trailer worked great! Tows pretty good, is good and stable when sitting on the legs and is convenient! Saturday morning there was a family turned up, they took ALL MORNING to set up.... crazy! We were set up in 1/2hr including putting up a tent in gale force winds (and the dark) for the friends that came along. The one thing that I will be changing is the layout on the storage side, originally I was going to keep it mostly open for boxes etc, but I think it will work much better if it has a shelf in there so that you don't have to dig through the stuff on top to get to the lower things.

Worst part of the trip (other than the wind) was that the dog chewed one of the trailer leads this morning before we left!!! :mad: Luckily he only chose the power for the camper. So the battery didn't get charged on the way home, worst of all though was that it also activates the pressurised air system! So on the way home there was a small amount of dust got it... not as much as I would have thought though. After the Mrs washed the camper I put it in the shed, was looking at it and noticed all the stone damage! We only travelled about 45kms on dirt road and there are what i would consider a large number of stone chips and dints on the front of the camper. The D90 must throw a lot of rocks! Maybe some sort of stone guard is needed.

On a separate note. I have some rhino rack roof bars, they have served me well. Today with the rough road the rear one seems to have rattled loose, then ejected the kayak!!! Luckily I was only going 60-70km/hr at the time. The Kayak did survive to tell the tail (well I think it has, hasn't been tested yet) but it does have the battle scars to prove it. I was very surprised that it didn't' go under the wheel of the trailer or that the car behind didn't run over it and kill themselves.

Next on the agenda will be the new shelf. Then onto the trailer, it's getting new spring bushes, lights, paint.

[Chops]

Good to hear it all went well :D

For the stone chips, an angled frame at the front with mesh in it should solve that problem,, or maybe a long mud flap right across the rear of the car.

[debruiser]

Yea i remember reading a thread recently discussing stone deflectors. I had contemplated one, until I read that they have a habbit of throwing the stones back at you. I'd prefer to ruin the camper than my 90. I'll have to think about that one for a while and come up with some ideas on how to do it.