'81 Grandby on '91 Jeep YJ - New build

[PokyBro]

Hey Boonie, what a score! Boy I'd say you're ending up doing many of the same things I did on my build. But, dude, you got your salvage camper for free, unreal! I paid $275 for my salvage camper, got what I needed out of it, and then sold the 3-way fridge, camper jacks, and stovetop, so I recovered my original cost, but you're doing yourself a big favor. And funny thing, same story, the Wyoming wind lifted the top off of the one I acquired as well. That can't be very fun to have happen, on a trip to or from, your camping destination.

I really chuckle, about your posts, because I think the same. These rebuilds are a real journey. You're always thinking ahead of next steps, and keeping an eye out for the things you'll be needing. Craigslist has been awesome for me, and I always enjoy meeting so many different people in the process. So many stories you here.

Anyhow, keep up the good work!

Poky


Sent from my iPad using Wander The West

 

[Boonie]

Poky, Shellback, Wuck, Dreamer (Living the Dream) and anyone else who may have followed my build in the past.

I am alive and well, however, the build has gone nowhere for almost two years now. My class C motorhome has been sold and I now have a 37' DP class A. Not exactly the boondocker my Jeep/FWC is designed to be, but as we have been doing some long term travel it sure is a lot more practical.
I finally found a pair of aluminum truck side load tool boxes that I could afford and which is getting me excited to get back to the build. ( I hope that sparked a question of: " what is he going to do with those?") Standby, give me a little time and I will post a update.
I also will be spending time reviewing each of your threads to get caught up.

Boonie

 

[PokyBro]

Boonie,

Welcome back! I’ve wondered more than once how you’re doing and what happened with your build. Can’t believe it’s been nearly two years.

Anyhow good luck as you dive back in, and remember to share some photos. Keep the dream alive buddy!

Poky

 

[Living The Dream]

Great to hear from you Boonie. Not finishing a project, I don't know anything about that. As my electrical components yet to be installed for 1+ year scream from a dusty corner of the shop

Glad to hear you are motivated again!

Thinking of organizing a Colorado meet up this summer. You better get your act together, I'm not sure there will be parking for A classes

Looking forward to seeing what you put together.

 

[shellback]

Glad to hear you are enjoying yourself out on the road! I'm kinda at the opposite end of the spectrum. I completed my build and not getting much use out of it. My wife has MS and it can be very trying for her. Just spent 5 days in the hospital, and now is in rehab. Hoping they can get her back in shape so we can hit the road a little more this year.

 

[So Cal Adventurer]

This is excellent!!

 

[Boonie]

In the last post (Jan 2019) I mentioned I purchased a pair of aluminum truck side load tool boxes, After spending the winter in my class A motorhome in Texas, I am now back in Colorado, so I finally got around to installing the right side. I thought you might like to see a picture of how I installed it since this is not a usual FWC rebuild,



Since my intended use is off the beaten path boondocking, having outside storage is a must to avoid packing and unpacking, lugging stuff in and out of the inside.

Now on to the left side which will be more complicated because of the refrigerator. I hope it will not take another year before that happens.

Boonie

 

[larryqp]

NIce, that outside storage looks perfect for my waders, boots, vest and 4 piece fly rod. Keep these posts coming.

 

[Boonie]

Well to get to the left side to work on that tool box, the frame for the top was in the way, so when I pulled it out I decided to narrow it while I had it out. In a previous post I mentioned that the camper was narrowed 11" to 69"wide. I believe that is the width of the Hawk model, anyway that is what works on my Jeep.



To keep the original strength, I cut out 5.5" from each side. At the front I staggered the cuts again to keep the original strength. (Shown before welding)

Now that that is done, I can get to the left side where I will have to cut down the tool box to allow room for the refrigerator. Stand by....

Boonie

 

[Boonie]

OK, got the refrigerator set, so the final size for the left side tool box has been established, 34", so I need to cut down the 48" tool box by 15".



With that set I can now continue with the mock up of the inside. Sink and portable stove with quick disconnect, so it can be used outside also, join the Porti-potti on the right-side. Not pictured is a 5 gal fresh water jerry can that tucks perfectly between the front end of the right-side cabinet and the jeep roll bar and a 5 gal grey water jerry can that will go beneath the sink.



Other major items have been located. 11 lb. propane tank will be in the left side tool box. 10 gal water tank will be behind the drivers seat partially in the previous foot well (4") and partially below the floor board (3 1/2") The water fill and water pump will be located in the left side fender well box. To balance the weight of the water, the house batteries will be located in the right side fender well box. Which means the 1000w inverter will be located in the toe kick area of the right side cabinet.

I'm still looking for the best place to mount the 120v/12v converter, the solar controller and the Trimetric. Oh, and the outdoor shower.

Boonie

 

[m.r.h.]

I started following this a few days back, pretty sweet. I also noticed that FWC posted a similar build on their Instagram a couple days ago. Excited to see how your build turns out.

 

[Boonie]

It seems like I'm out in the garage working, but what I get done doesn't show. A lot of thinking, measuring and head scratching. In post #60 I said I was planning to locate the propane tank in the left side tool box. Well, after not really liking that decision, I measured the left side fender well (just below the toolbox) and found it would fit. Keeping in mind my commitment to keeping the weight low and centered on the wheelbase. I will now have two six volt house batteries, 10 gallon water tank and the 11 lb propane tank located in a line ahead of the rear wheels, behind the seats, and at or just above the level of the frame and outside of the living envelope.

I feel better with this solution.

I also have a 20x18x4 space under the floor that can house the water pump or I could fit a second 10 gal water tank that I have, but it is 7 1/2" deep, so to fit I would have to raise the floor 3 1/2". Not sure I want to do that. I think carrying the 6 gal Jerry can fits my needs better.

Now on to cutting the aluminum to frame the rear overhang, so I can get that welded.

 

[Boonie]

Welding the extension day 1.



Should be able to square up and finish welding tomorrow

 

[Boonie]

Welding complete, now final fitting before welding to the original shell. You can also see from the picture how handy the side opening toolbox is.

For those who are new to my (slow) build. I started with a '91 Jeep YJ which I extended the wheelbase 24".Then taken a '81 Grandby, removed the wood floor pack, narrowed it 11", removed the front wall (so it is a walk-thru to the cab) pushed the camper forward so the bed was extended to the windshield. (Camper inside is now 7'.) This resulted in a 22 1/2 " rear overhang which needed to be supported thus the extension, welded out of aluminum keeping with the original design.

 

[Zoomad]

Looks great!

 

[longhorn1]

Nice job

 

[Boonie]

No big deal, but it is sometimes the details that are the most satisfying. I have had a basic idea of how I was going to join the square camper to a rounded roof of the Jeep. As you can see I used the technique that FWC used to make to rounded front bed.

 

[Zoomad]

Great work. Looks like a good fit.

 

[PokyBro]

Very creative way to do the radius around the cab. Will you be welding anything on the top of the curve over the cuts, to stiffen the metal in place?
Also, did you end up purchasing a tig welder and learning to weld aluminum, or has that been a skill you acquired long ago? Either way, very impressive, not many of us are qualified to weld this thin speck aluminum tubing, great job Boonie!

 

[Boonie]

Alas Poky, the cost of a TIG welder and equipment, not time to learn, dictated that I had the welding done. Fortunately my son-in-law was a long time friend of a welder, therefore, Woody Glover has done (and will do) the welding for me at the cost of a new bottle of argon gas, $66.38. THANKS Woody!

I will be adding a member at the top that runs from the outer frame to the segmented member (which will attach to the bottom of the bed), then facing the resulting panel. My hope is that this panel tied to the segmented member will add the rigidity necessary without having to specifically weld it. At the end of the segmented piece, the distance between the bottom of the bed and the top of the Jeep is one inch and decreases to zero in the middle of the roof thus creating a thin wedge shaped gap, so I am contemplating how to complete the seal between bed and roof. Both the bed and the top are anchored at the mid point to the Jeep roll bar and to each other at the roll bar, thus, no movement between the two.

Ideas anyone?

Boonie

P.S. I am also thinking of a way to fill the entire space between the roof and the bed with foam insulation. This could be part of the solution.