Building the Ultimate touring 130 with slide on - my version...

Ok, decided to jump ahead a few steps and start building the slide on camper so we can give it plenty of test runs before the big trip. And so I feel like I'm getting somewhere! I've researched a few different building materials and have settled on using ACP (ally composite panel) with a folded ally frame (not RHS or SHS) on a reinforced plywood floor. I was keen on the 30mm fiberglass composite panels as you don't need a frame, but it would've been alot more dollars. Never used the ACP so here's hoping it will work out! Should be good as it is very rigid and fairly light and it comes in a choice of colours so no need to paint. For a weight comparison between 4mm ACP and 2.5mm ally sheet in a 1500 X 3600 sheet size, the ACP is 10kg lighter, and a lot more rigid.

Have collected most of the bits now, just need a bucket load of rivets!

https://www.aulro.com/afvb/images/im...014/09/780.jpg
https://www.aulro.com/afvb/images/im...014/09/781.jpg
https://www.aulro.com/afvb/images/im...014/09/782.jpg
Hopefully will get started in the next couple of weeks.

Andrew.

Have made a bit of a start. Firstly made up the base, which is 12mm ply painted with a good varnish surrounded with folded 2.5mm ally, and some folded top hat sections underneath to give it plenty of strength.
https://www.aulro.com/afvb/images/im...14/10/1314.jpg

The frame is 2.5mm ally folded into sections with a recess for the doors and I will pop rivet the alluminium composite panel (ACP) to it. I've decided to pop rivet the whole thing together as I believe it will be stronger than welding which can crack when exposed to lots of abuse/corrugations etc. Being welded might be ok but I'm sure the rivets will be better, its good enough for aeroplanes. To make it easier to build I just tack welded it together to hold it in place before riveting together.
https://www.aulro.com/afvb/images/im...14/10/1315.jpg

To tie the corners together I made up some three sided caps out of gal sheet.
https://www.aulro.com/afvb/images/im...14/10/1316.jpg
https://www.aulro.com/afvb/images/im...14/10/1317.jpg

Here it's upside down, ACP roof in, and the chute for the oztent in.
https://www.aulro.com/afvb/images/im...14/10/1318.jpg

Are now working on my quick release leg design before I can do much more.

Looks good Andrew,
I was up your way on Sunday, if it hadn't been so late I would have dropped by to see how it was going.

Tony.

Quote:

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Originally Posted by TonyC

Looks good Andrew,
I was up your way on Sunday, if it hadn't been so late I would have dropped by to see how it was going.

Tony.

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No worries Just let me know if you want a look.

Andrew.

Rivets have also stood the time on series , Countys ,Defenders;)
Good work very nice:D

Quote:

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Originally Posted by rangieman

Rivets have also stood the time on series , Countys ,Defenders;)
Good work very nice:D

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Must admit I did get some inspiration from looking how my 130 is made :)

Made a start on the legs. The longest part was deciding what method to use for attaching the legs to the camper. I made a prototype of an idea I had for a no tool quick release system, but I wasn't convinced it would be rigid enough. From looking at many other slide on camper units over the years I know many of them are wobbly when on their legs and often require braces/cross cables etc to help steady the unit. I'm determined to hopefully make it sturdy and quick to set up without needing the said braces or cross cables. I've settled on a version of my first idea which uses two big key holes for each leg.

All the bits cut out and a prototype to test it works.
https://www.aulro.com/afvb/images/im...014/10/920.jpg

I made a template to ensure all holes are the same so any leg will fit any corner. Also note I've fitted the gal corners to tie it all together, there is also a gal channel inside, all riveted together, makes a good strong mount for the legs.
https://www.aulro.com/afvb/images/im...014/10/921.jpg

I drilled the big hole with a hole saw, cut the slot with a jigsaw and cleaned up with a burr grinder and file.
https://www.aulro.com/afvb/images/im...014/10/922.jpg

Sorry haven't updated for a while, is hard enough to find time to actually work on the camper! Been chipping away, got the legs finished and the main shell done. With the camper fliped upside down I glued and riveted the oztent chute and end walls in.
https://www.aulro.com/afvb/images/im...14/11/1145.jpg
Where I didn't want the rivets to stick into the tent chute I drilled 12mm holes and plug welded with ally in my mig. Worked well.
https://www.aulro.com/afvb/images/im...14/11/1146.jpg
The oztent chute works well. I put a divider in so other long things like fishing rods and tent poles can be stored too. I'm yet to make the lid.
https://www.aulro.com/afvb/images/im...14/11/1147.jpg
Standing on it's legs. I'm happy with my leg attaching system, is no wobble or play at all, but the whole thing will still wobble a bit just from the legs flexing. I used proper ally scafold tube 4.5mm thick which I thought would have been a bit more rigid, but it's still alot better than others I've looked at. Will see how it is all loaded up, worst case will need cross bracing. I'm also wondering if I splay the legs out slightly if it will help?
You can now get the gist of my set up. You can see the oztent chute protudes forwards about 300mm, and out the back about 100mm. It's like this because the oztent is 2000mm long, tray is only 1800mm long and I'm putting the two spare wheels on the head board, so they will stay with the vehicle when the camper is removed. I could have put the wheels under the tray but I wanted to keep the tray as low as possible for my short wife, and I'm keen to build a big slide out drawer at the rear under the tray to store tools, parts, and stuff that needs to stay with the 130. The chute will just fit nicely between the wheels and uses otherwise hard to use or dead space up high and in the center of the camper. It will also make deploying the tent quicker, simply open the rear hatch, no messing around with rachet straps etc and It's out of the elements when travelling.

You can also see the frame work for my idea to solve one of the other complaints people have with a RTT, that being the skinny little ladder can be awkward climbing in and out of the RTT. I'm bascially making a big slide out drawer with the side open. You will simply swing your legs out of the RTT onto a solid platform, then down a step ladder with wide treads. The drawer will obviously need to be empty, so I will be storing all the camp chairs inside which you need out anyway. Next step is to make the said drawer/platform and all the doors.
https://www.aulro.com/afvb/images/im...14/11/1148.jpg

Did a trial fit yesterday, all works well, and was great to see it fits and looks like I'm getting somewhere.:) The air suspension really does make it easy to take on/off, was great to see it actually works as planned! Took about 2 mins from time you stop, level, set legs up, drive forward. Is fairly easy to back under also. If you had to mess around with jack legs would take way longer.

Cheers,
Andrew.
https://www.aulro.com/afvb/images/im...14/11/1093.jpg

https://www.aulro.com/afvb/images/im...14/11/1094.jpg

https://www.aulro.com/afvb/images/im...14/11/1095.jpg

Starting to think about setting up the kitchen, fridge slide, drawers etc. I have a bit of an idea but are open to suggestions on a good set up for all the cooking gear, food etc.
Cheers,
Andrew.