84 Fleet - 09 Tacoma - Project

[Living The Dream]

Thanks for the details in this thread Tim! Just bought myself a used FLEET and I'm gonna be referencing your work quite a bit.

Awesome JT. Looking forward to reading your build thread. Get some before photos going!

Tim, are you still using the original sideliner or have you tackled making a new one?

Boonie

Boonie. My sideliner is off the camper and will not be going back on. I will make my own. Around Christmas I got samples from:

18 oz. Vinyl Coated Polyester Fabric by the Yard - 61" x 1 yard - 18 Colors | eBay

Ill go with the 22oz. Probably gray colored. Around Christmas I also went and met up with Poky, who gave me a grand tour of his build and we extensively chatted about the sewing. I think I have a clear picture of what I need to do. Not much progress on my build recently. Slowing chipping away but I have been spending too much time skiing

and snowshoeing

Winter is what I bought the camper for, but its not ready. So I have a catch 22 of working on the camper to get it ready for winter, or enjoying winter. A very privileged dilemma.

I noticed on the cab over bed plywood there seems to be a track or metal framing down the middle. Can you tell me what that is? The Grandby I just picked up doesn't have that, although there is a seam down the middle of the plywood. I think that's due to someone replacing the plywood and had to do it in 2 pieces, otherwise they would have had to remove the paneling. Thanks, Ron

Hey Ron, Can you point me to what picture you are referencing? My cab over plywood was replaced by the previous owner so whatever I have is probably not stock. It is also two pieces. Down the middle is a piece of wood, not metal. Also, when I received the camper there was no wall paneling in the cab over area so you may be correct the panels have to come off to drop the cab over in. I'd strongly suggest you sand the heck out of your new plywood and give it a nice stain, just cause I think it looks rad

I do want to add a simple 1X4 on the exterior running between the two plywood pieces to sure things up a bit. I actaully noticed the wood glue cracking a bit and some light can shine through.


Thanks all for the comments, it was fun to think about WTW and my TC again. Ill have to get back into the camper soon. I do have some progress I could write about. Ill get some good photos and report back soon.

 

[shellback]

Okay and thanks for the reply. I thought there might have been a track for support of the extended bed, but I see it's a joint in the plywood.Although my 2 piece is in good shape I think I'll replace it with one piece of 3/4. My camper had no remnants of the lift panels, just some funky decking boards with a hinge to hold up the top. I'll be going with the electrical conduit fix. Was that 3/4" tubing? I have a question on the side liner. Seems like a lot of work pokey did to have the screen, clear window, the closure panel. Has anyone considered doing away with the windows and just make a windowless liner? The wife and I only camp spring and fall. She has MS, and the heat in the summer wipes her out. So for ventilation , I don't think I'll need the extra area. Thanks, Ron

 

[Living The Dream]

Yes, 3/4in tubing for emt. Ill be posting a full report of making mine sometime soon. I redid the bottom bracket for the lifter.

And yes the windowless linear has been done. Can't recall the build off the top of my head but I know of at least one. If you go windowless you could probably do the linear in an afternoon or weekend at least.

 

[shellback]

Thanks!

 

[Boonie]

Tim,
Since I still have to do my sideliner and I was thinking you would be doing yours, I was thinking of a sewing class taught by Poky, but since you have the knowhow, I will anxiously await working along side you. Keep me posted, (but I hope to have mine done by Memorial Day. No pressure just sayin'.)
Boonie

 

[Living The Dream]

Tim,
Since I still have to do my sideliner and I was thinking you would be doing yours, I was thinking of a sewing class taught by Poky, but since you have the knowhow, I will anxiously await working along side you. Keep me posted, (but I hope to have mine done by Memorial Day. No pressure just sayin'.)
Boonie

My goal is to at least get a few ski night in Later march and April so I will do my best.

 

[shellback]

I have a friend in NC that had a commercial sewing business. He still has a few machines and he said I'm welcome to one. It does need a motor, as it has a 3 phase motor on it now. I'm going to buy a motor and have it shipped to him, about $120.00. Once he has it set up. I'll go get it, and get a little fishing in at the same time. Shame we aren't closer and could share it. I'm going to order a little extra material and give a try at the windows. If I make a mess of my sample, I'll just go without the windows. Another alternative is to have a friends wife do the windows for me. She has a sewing and embroidery business.

 

[lindy74]

Lifter Panel Replacement:

The brute force and 2X4 lifter panel worked moderately okay, but I knew I wanted to something a little easier, better, and less likely to tear the canvas.

I got in touch with FWC and the are happy to sell new composite panels. At $450 it was simple not a smart move to spend more then I bought the camper for one lifter. Plus they are only installed at the factory in California so that wasn't an easy option either.

Luckily WTW is a ridiculously good resource and I saw wvtradbow post showing his lifter made of EMT conduit. http://www.wanderthewest.com/forum/topic/10761-this-old-granby-build/page-3.
I think the total cost was less than $30 for me, so it was an obvious choice.

All that was left from the old panel was one piano hinge that I had to drill rivets out to remove. I might use this for my bench down the road, but if anyone is in need of one of these get in touch with me and I can pass it on.

I bent my two pieces of conduit just like wv explains. Except I also added more curves on the bottom of the lower bracket as you can see in the photo.

This allowed me to use simpler brackets to get the pivot at both the bottom and top without sticking into the bed area much more. Double Cicada Brood 2024

Notice the far right screw going into the conduit, it is there to keep the conduit sliding horizontal and the roof become off center of the base.

Protip, the hinge point has to be at the height mid point. Not sure what I was thinking when I started but the extra hole works great for the pins to secure it.

I am supper happy with how the whole thing turned out. It works absolutely great. Only draw back is when collapsed it does take up all the space in the cabover, so the mattress needs to go down on the bench.

I can not thank wvtrad enough for answer my question about his design. You can see my conduit bending skills are a little young still, but considering its the first time I have ever bent pipe it works great. I will not hesitate to use this for the rear panel if that should ever fail.

First off, all the guys that came up with these lift tubes, great idea! One thought I had was installing them East and West. Phoenix uses a system like that but has tracks on the roof. If you used your system but side to side with the struts still North South it might work and not encroach on the cabover bed.
Just a thought for discussion.

Here's the link to the phoenix lift bars:

 

[Living The Dream]

[SIZE=11pt]It has been a while since I updated this build (or really put much work into the camper). This winter was full of skiing, traveling, and now biking, so I really did not have a lot of time for the camper. [/SIZE]

[SIZE=11pt]https://www.youtube.com/watch?v=KXo2Fyc84Gg[/SIZE]

[SIZE=11pt]https://www.youtube.com/watch?v=QK2z46faXKs[/SIZE]



[SIZE=11pt]Completely blew the timeline of this build, but ohh well such is life. I am back at it working on the camper and things are starting to come together.[/SIZE]

[SIZE=11pt]I am feeling a bit under the weather this weekend so will lay low and catch up on some documentation of the camper build. I have also started making videos of the build that I will edit into some informational/fun videos in the future. I’ll be sure to post links when they are ready.[/SIZE]



[SIZE=20pt]Roof Build 1[/SIZE]
[SIZE=11pt]The rest of the roof build went pretty well. I ran wires for four overhead lights! Probably overkill but since I plan on using this camper in the winter I know there will be a lot of dark long nights so I think the excess light will really pay off. Plus the bulbs are all LED so power draw will be minimal.[/SIZE]

[SIZE=11pt]First drill holes in the frame to pass wire through. I used a little vacuum line I had lieing around to protect the wire from the metal edge.[/SIZE]

[SIZE=11pt]I recently bought 200ft of both red and black wire off of ebay. I think 16 gauge should be fine for lights, fans etc. http://www.ebay.com/itm/271210442082[/SIZE]

[SIZE=11pt]The wire was really nicely priced and seems good enough. No real complaints so far. I ran that to four areas in the roof.[/SIZE]

[SIZE=11pt]Taped everything down and should be good to go.[/SIZE]

[SIZE=11pt]I did take extensive measurements incase I ever need to find a wire in the roof again. But that would be a bad day, so hopefully I never need those measurements[/SIZE]

[SIZE=11pt]I also ran wires to the vent area. I do not currently have a fan but the wires are right there, ready to go if I ever choose to upgrade.[/SIZE]

[SIZE=11pt]Before I go any farther, it was time to check the wiring was correct and the lights actually worked. Here are the lights I bought, two double and two singles. All LED bulbs.[/SIZE]

[SIZE=11pt]And we are in good shape! Ready for insulations now.[/SIZE]

[SIZE=20pt]Solar wire[/SIZE]

[SIZE=11pt]A quick side note, I also ran my solar wire before putting insulations down. Again getting measurements and photos of where the wire lives incase I need to get at the wires someday down the road. For the solar I ran 10 gauge stranded copper wire. Way overkill for the small panel I have now, but now the wire can easily handle a panel upgrade later. Plus the bigger the wire, the less resistance, so it will help me get every drop of sun into the battery. [/SIZE]

https://www.amazon.com/gp/product/B00INVF468?psc=1&redirect=true&ref_=oh_aui_detailpage_o01_s00

Roof insulation
[SIZE=11pt]With all the wires down, it was time for the roof insulation. I debated between soft and rigid insulation. In the end I went with soft as that is what the guys at ATC told me they use in new campers. I think the main issue with rigid is squeaking in windy conditions but maybe that is just internet chatter and it actually works great?[/SIZE]

[SIZE=11pt]In the end [/SIZE][SIZE=11pt]this is the product[/SIZE][SIZE=11pt] I used. Some 2 inch fiberglass duct insulation.[/SIZE]

[SIZE=11pt]It was as simple as laying down the insulation and cutting to fit.[/SIZE]

[SIZE=11pt]After all the insulation was down it was time to check the lights again. And lucky me, everything still works![/SIZE]

[SIZE=20pt]Wooden ceiling supports[/SIZE]

[SIZE=11pt]Not quite sure what to call these wooden strips, but I know the old camper had them so I made new ones. I just ripped a common board into strip ¼ in thick and boom have all the strip I need. Some staining, drying, and poly coating and they should be good for a long time to come. I also took care of a few other pieces I needed such as the lifting push panels and some parts for the bed slide out.[/SIZE]

[SIZE=11pt]For reference all this work was done in late November 2016.[/SIZE]

 

[Living The Dream]

[SIZE=20pt]Headliner install [/SIZE]
[SIZE=11pt]With the roof wired and insulated it was time for the headliner. I bought the same product many others suggested, the marine grade headliner from upholsterysupplyonline.com. It was a little pricey but is definitely of high quality.[/SIZE]

[SIZE=11pt]http://www.upholsterysupplyonline.com/products/Marine-Headliner-White-HDL%252d1004.html[/SIZE]

[SIZE=11pt]The roof is wider than the headliner material so you run a seam down the middle. [/SIZE]

[SIZE=11pt]I used this 3M spray to put the headliner down, it works great and I have used it for countless other things since then too.[/SIZE]
[SIZE=11pt]https://www.amazon.com/3M-90-24-Spray-Adhesive-17-6-Ounce/dp/B0002BBV2S[/SIZE]

[SIZE=11pt]With all the fabric down, it was time to install the wooden runner supports.[/SIZE]

[SIZE=11pt]With thin wood like this, it was important to properly drill holes for the screws.[/SIZE]

[SIZE=11pt]While I was doing all this I also prepped all the roof trim for later reinstall. Brown for everything![/SIZE]

[SIZE=11pt]And the finished product came out great!!! Truly something to look up to [/SIZE]

[SIZE=11pt]For reference this work was done in late November 2016[/SIZE]

 

[Living The Dream]

[SIZE=20pt]Passthrough lids[/SIZE]
[SIZE=11pt]A quick project that I could check off the todo list one afternoon. I used some spare plywood and left over panelling to make new passthrough lids. Three passthroughs are just holes in the top that are easy to put a lid on. A little glue, a quick clamp, some paint, and voila a lid. I did use a bit of [/SIZE][SIZE=14.6667px]weatherstripping [/SIZE][SIZE=11pt]to help with sealing out the cold air. I will add some sort of latch in the future but that is low priority.[/SIZE]

[SIZE=11pt]The last passthrough was slightly more complicated as it accessed from the side. But I added a two hinges and all works well. [/SIZE]

[SIZE=11pt]I like projects that are quick and easy [/SIZE]

[SIZE=11pt]For reference this work was completed in December 2016[/SIZE]

 

[Living The Dream]

[SIZE=20pt]EMT roof lifters[/SIZE]
[SIZE=11pt]I put this project off as I was a bit afraid to tackle it. It took me quite a few weekends but in the end came out great![/SIZE]

[SIZE=11pt]As I have discussed in the past I just didn’t want to buy the new composite panels because of the price. But also because I wanted to add more height to my interior ceiling. Since I am making the canvas I have that option and ended up going with a 6’6” interior height! No more ducking around inside the camper. [/SIZE]

[SIZE=11pt]It is pretty tricky to figure out how to get the pivots location correct, bend the conduit at the right spots, etc. I do have a ton of measurement sketches but will opt not to post those as I did a lot of shooting from the hip as I progressed. One thing you need to make sure of is that there is room for the top horizontal tube when in the down position. To accommodate that you need to have your lower pivot be below the camper body top. I think the pictures will help clarify.[/SIZE]

[SIZE=11pt]1st bending the emt, I got pretty good at this by the end. My main suggestion, use a level and level ground to tweak all the angles to 90.[/SIZE]

[SIZE=11pt]Then it was time to figure out the the lower pivot system. Like everything on this camper it was time to learn some new skills. After trying a few different options with stock parts from the hardware store I finally just made my own brackets. A friend lent me his shop and I cut the sheet metal and stock with the bandsaw and shearing machine. Didn’t do 100% perfect but I got the job done.[/SIZE]

[SIZE=11pt]There is a lot of pressure down at that lower pivot so I wanted it really secure. That is why I made these spaces and the oversized brackets backing panels to really tack the pivot bracket to the side wall. Some other things to look out for it to make sure the tube has clearance away from the wall to make the rotation. If you want to go this route just get in touch with me and I can try to offer more advice.[/SIZE]

[SIZE=11pt]It was pretty cumbersome and stressful to get it all in place and together. Took a lot of guess and check but eventually it went together nicely. And hey it works! Fits in both the up and down positions. [/SIZE]

[SIZE=11pt]And of course after I knew it worked, I took it all apart and painted it to match everything else. I also used some table end caps to give the tube a finished clean looks[/SIZE]

[SIZE=11pt]The middle pivot and locking pin[/SIZE]

[SIZE=11pt]The top support attachment just uses stock emt hardware. Three on each side.[/SIZE]

[SIZE=11pt]It was a tough problem to solve but very doable. I would suggest this to anyone doing a rebuild and not wanting to but the panels from the dealer.[/SIZE]

[SIZE=11pt]Something I will need to deal with in the future is that in the bed area the lifters take up a lot of volume in the down position. I might have to put mattress down to drop the roof. A bit of annoyance but I will cross that bridge when i get to it.[/SIZE]

[SIZE=11pt]But look at all this headroom![/SIZE]

For reference this work was done in January and February of 2017.

 

[Living The Dream]

[SIZE=20pt]Bed pull out[/SIZE]
[SIZE=11pt]Another rather quick few-evening-task was the bed pull out. There was a nice piece of ¾ in plywood that was with the camper when I bought it, so I kept that. A little sand, stain, poly and it looked great. [/SIZE]

[SIZE=11pt]I had some left over UHMWPE from another project so I made four slide bars to try to reduce wear on the wood. I counter sunk the screws and used glue when I installed them to the bottom of the pull out.[/SIZE]

[SIZE=11pt]I also rounded the corners with a jigsaw so they fit into the camper closer. This allows the bed to be pushed in fully when in the closed position and won’t bother someone sitting on the bench with their back to the bed.[/SIZE]

[SIZE=11pt]Then I just installed the supports on the wall just like what was there before. I think FWC still uses this type of support today.[/SIZE]

[SIZE=11pt]There is support along the front wall too.[/SIZE]

[SIZE=11pt]Pulled out[/SIZE]

[SIZE=11pt]I still need to make a front finish piece like what Poky just built.[/SIZE]

[SIZE=11pt]http://www.wanderthewest.com/forum/topic/12116-new-build-1981-grandby-to-become-a-hawk/page-20[/SIZE]

[SIZE=11pt]That piece is definitely important to give the plywood extra rigidity. I’ll be sure to finish that off nicely in the near future.[/SIZE]

[SIZE=11pt]For reference this work was completed in January or February 2017.[/SIZE]

 

[Living The Dream]

[SIZE=20pt]Rebuild door[/SIZE]
[SIZE=11pt]The ski season might be winding down, but bike season is kicking up and just as distracting.[/SIZE]

[SIZE=11pt]https://www.youtube.com/watch?v=CFVjgt68Tu4[/SIZE]

[SIZE=11pt]I was going to start the sewing project, finally, but had a few set backs so I took care of one more issue that was nagging at the todo list. The old door was in tough shape! The bottom piece had rotted off, someone had obviously tried crowbar in at one point in time, the door just needed some love.[/SIZE]

[SIZE=11pt]I took everything apart and used the old frame as my template.[/SIZE]

[SIZE=11pt]I recently got a new saw so I also built myself a little cross cut jig.[/SIZE]

[SIZE=11pt]With a bunch of clean square corners thanks to my new saw, the frame came together in a snap.[/SIZE]

[SIZE=11pt]With the door being a unique thickness I had to improvise for the insulation which I was able to do with some reflective and 1” rigid foam. It actually worked out really well. A quick note, 3M 90 adhesive will eat rigid foam insulation.[/SIZE]

[SIZE=11pt]I did a little JB weld/beer can (La croix) fix in an area of the sheet metal someone broke before.[/SIZE]

[SIZE=11pt]Then it was time for more paint.[/SIZE]

[SIZE=11pt]And the final product came out awesome. For some reason I was really excited how this came out. Really a nice finished look and very motivating to push through to the near end of this project.[/SIZE]

[SIZE=11pt]We made the inside an accent color and it stands out really well.[/SIZE]

[SIZE=11pt]This work was done this week, June 2017. Back at it with night and weekends. I swear the canvas liner will be my next project. Or maybe I will get distracted with the electrical [/SIZE]

 

[Living The Dream]

I have a friend in NC that had a commercial sewing business. He still has a few machines and he said I'm welcome to one. It does need a motor, as it has a 3 phase motor on it now. I'm going to buy a motor and have it shipped to him, about $120.00. Once he has it set up. I'll go get it, and get a little fishing in at the same time. Shame we aren't closer and could share it. I'm going to order a little extra material and give a try at the windows. If I make a mess of my sample, I'll just go without the windows. Another alternative is to have a friends wife do the windows for me. She has a sewing and embroidery business.

Shellback, did you ever get the machine and tackle the project. Would love to hear an update.

 

[Living The Dream]

First off, all the guys that came up with these lift tubes, great idea! One thought I had was installing them East and West. Phoenix uses a system like that but has tracks on the roof. If you used your system but side to side with the struts still North South it might work and not encroach on the cabover bed.
Just a thought for discussion.

Here's the link to the phoenix lift bars:

Hey Lindy,

Yes I have seen them in the other orientation; both in the Phoenix and also in some custom van pop ups. I just updated with a post detail my new lifters. I am happy with the North South panels but would love to see yours if you go with something else. - Tim

 

[GoinBoardin]

Thanks for updating. I too am a grad student (just north of you in Wyoming), rebuilding an old FWC, but being distracted by biking and earlier in the year, snow fun (snowmobiling). I'll be following your foot steps on the EMT lift mechanisms very soon (exterior canvas is here, new headliner on the way) and appreciate your detailed pictures & tips. I recently built a slide out bed just like Poky's too. Just wanted to say, keep it up and thanks for sharing!

 

[Living The Dream]

Thanks for updating. I too am a grad student (just north of you in Wyoming), rebuilding an old FWC, but being distracted by biking and earlier in the year, snow fun (snowmobiling). I'll be following your foot steps on the EMT lift mechanisms very soon (exterior canvas is here, new headliner on the way) and appreciate your detailed pictures & tips. I recently built a slide out bed just like Poky's too. Just wanted to say, keep it up and thanks for sharing!

Thanks, glad you are tackling a project too. Would love to see your build documented too! Let me know if you have any questions.

 

[Living The Dream]

[SIZE=20pt]Quick lights install.[/SIZE]
[SIZE=11pt]I did a bit of work this weekend. Besides sketching out the rest of the canvas sewing plan, I installed my four overhead lights. I bought these 12 V LED replacements a while ago. The amazon link is dead but this was the product information:[/SIZE]

[SIZE=10pt]YITAMOTOR 10 X 1156 BA15S 68-SMD RV Camper Turn Signal Warm White LED Light bulbs 1141 1003[/SIZE]

I am very happy with the lights.

A couple of butt crimps and we were good to go. Easy peasy and have a ton of light. These photos were taken in the garage with all other lights off and doors closed. With all 6 lights I was still only pulling 1.6Amps which means I will definitely be good for many days even without any solar.

[SIZE=10pt]I swear I’ll sew my canvas soon.[/SIZE]

[SIZE=10pt]For reference this work was done in early June 2017.[/SIZE]

 

[ski3pin]

Your work is fun to follow. Thanks much for the updates!