Eagle Shell buildout

Thevulture

Advanced Member
Joined
Sep 14, 2017
Messages
39
Location
Los Angeles
We purchased our Eagle used off Craigslist in March of '18, it's a '16 model and is practically brand new (I think the previous owner used it about 10 times). The previous owner had it built from FWC with the side dinette (we were unsure if we would like it at the time, but we really love it and it makes for comfortable living space), he also had it built out with a propane box (no heater) and roof tracks. We wanted a shell model because of the flexibility of adding our own stuff and keeping it simple and functional, but we were looking for any Eagles, as they are so hard to find. This ended up being a great deal and we had to jump on it.


-First day after picking it up in Prescott.

We were using my old chuckbox for the first few months, while I tried to figure out exactly how it would work out and where stuff would go. The chuck box is great, but it weighs about 60lbs. loaded and I was getting tired of lifting it.


-Unmodified interior
The first thing I added was a top loading Engel fridge and it’s been great. If I were to only do one add on, it would be the fridge. Second, I bought some used Yakima Towers off Craigslist and went to the metal supply and bought some 6061 aluminum tubing and sprayed it with Plastidip ($20 instead of $100 from Yakima). I installed my Thule roof box and this has been great storage for camp chairs, wood, and the camp table. It's heavier than I thought it would be and will eventually upgrade the struts to 50lb.

-Fridge (notice how I made a cut so I could still access the storage and fuses via the hinged door)


-After installing roof box, near Great Basin NP in Nevada.
After using and learning the camper through the spring and early summer I decided to do a simple cabinet and install a Propex heater. I removed the carpet and hinged door and covered it with plywood and created a removable cover to access the fuse block and small tool storage. From there I removed the siding and mapped out where all the aluminum studs are, drew it out and then placed tape on the siding to make mounting the cabinets easier.

-Stud "blueprint" and tape markings.
I made the cabinets and finished them outside (to keep the dust out) and assembled them inside the camper. I also redid the wood for the propane box so it would all match and I may redo all the wood inside sometime. I used 1/2" Baltic Birch for the the cabinets and 3/4" for the countertop. If I were to do it again, I would use 3/4" for everything except the cabinet doors. I finished it with a water based stain and 6 coats of water based poly. I used slam latched similar to what FWC uses, that I found on Amazon.

-Guides for router to make the face of the cabinet.

-Checking fit before installing doors and making holes for the heater vents. (Notice the access door to get to the fuses and storage. The black cover on the propane box allows for quick and easy access to propane line and power for the heater. The CO alarm is mounted there now and the thermostat will be mounted there too. It's pretty low to the ground and hopefully it's a good spot for the thermostat.)

-Finished, 10pm before the 3 week trip!

I don't have much experience building and this was the biggest project I've done. It took me longer than expected and I had a lot of mistakes, recuts, mis-measurements, and a few curse words, but I think it came out very nice and I'm quite proud of it. We used the camper in for three weeks this summer and it was great to not lift the chuck box up and down everyday.
I thought about installing a sink and stove, but we don’t really like to cook inside the camper, but can fire up the Coleman white gas stove and make coffee on cold mornings (I open a turnbuckle door and crank the roof fan to get the air moving). I have two 7 gallon jugs that give us about 2-2.5 days worth of water for cooking and cleaning.
My plan for the heater is to mount inside the cabinet and vent out. I bought the Propex HS2211 model specifically because it can be mounted on it’s side. I will use this boat through hull vent out to route the exhaust and intake from the back of the camper. I plan on doing the heater install this month and will post updates.



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-Thru Hull Fitting
 
Thanks ski3pin, I've enjoyed reading your trip reports and build writeup. I grew up in Tahoe City and it's nice to see those places in your trips.
 
Nice find, and interior work there Thevulture. We have the same Engle fridge and base, fridge popped out a couple time so I have two straps pulling the fridge into the base. No more problems for us. Not saying yours will experience the same problem. Probably one strap would be ok. Just a heads up, and we were on some rough roads in Death Valley. Looking forward to the next mods


Russ
 
Thanks Russ, we haven't had that happen yet, but I may look into it before I do any Baja or Death Valley trips.
 
Hi TV,

Welcome to the forum, and thanks for sharing the start of your Eagle build out. I really like what you’ve done so far, and compliment you on your efforts. The cool thing about adding things to your camper is learning as you go. Most of the time you are the only one aware of mistakes. Shoot, I bet there are mistakes on factory made campers all the time. Anyhow good luck, and looking forward to more of the additions you make.

Poky
 
Looks really nice. i did a similar cabinet build, used 3/4" for the cabinets but realize now should have gone thinner for the cabinet faces, but the red oak I used looks good. The Propex furnace should be great, that is what we put in. I really like the Thru-Hull fitting, that should work really nicely. The good thing about building it yourself, is you can change it as you need to in the future. As for the mis-measurements, refitting, etc, that certainly comes with the territory if you don't do if for a living. When I have a gnarly carpentry issue I have a friend help who is a master and he always shakes his head and laughs and tells me it's a good thing I am not trying to make a living at it. Have fun!
 
Be wary of 50# struts. The struts are exerting force the entire time the top is down. Four Wheel recomends no more than 40 and preferably 30 for most applications. I think 50 will put a lot of stress on the connection points. There have been discussions about it on this Forum in the past or maybe on the Four Wheel Campers Facebook page.
 
An alternative to using the 50# struts which FWC does not recommend is to get an "In Concert Music Speaker Stand" and remove the tripod legs. It will take the stress off of the roof panels when raising the roof with a load up there. I love mine because it lifts the roof up high enough that I just have to give the panels a little push to lock them in place.
 
Vulture,

Thanks for sharing your build process. I like the simplicity of what I think you are trying to do. I have a new Ocelot shell on my truck and hope to get stuck into my build in the new year. My intention is to keep it simple and light. I will be keeping on eye on how you proceed to see what I can learn. You seem to have made an excellent start.
 
I finally got around to installing my Propex 2 weeks ago. I used the Propex thru hull as my vent/intake, it looks really nice, but it's more designed for boats with thin hulls. If I were to do it again I would use something different. I had to remove quite a bit of material from the inside of the camper to make it work. It's not pretty, but no one will ever see either.
Here are photos from the outside and inside (hose clamps were eventually installed to secure the intake and exhaust)




One of the main reasons I went with the HS2211 was because it can be mounted on it's side, this allows me to still have a little bit of storage. Instead of using copper tubing I had hose made, it allowed me to get it through the super tight areas. I used a fiberglass heat sleeve to cover the exhaust to keep it cooler and avoid burning anything, I don't know if it's 100% necessary, but I like the peace of mind. I plan on eventually taking a IR temp reading, I'll share the numbers. I also put some aluminized heat barrier to reflect any heat on the counter top. Also not 100% sure if it's necessary, but the peace of mind is nice. Both were purchased off of Amazon.
I was originally planning on mounting the thermostat low, near my CO monitor (the black rectangular area below the cabinet), but after reading more I learned that it should be mounted higher. It's now in a convenient spot on the corner.





I plan on doing the first night with the heater this week when I go skiing up in Mammoth. I'll let you all know how it goes. Thanks for the kind words and checking out my build.
 
It's been awhile since I gave an update on my build. I also realized my links weren't working, sorry. I've had the Propex installed for about 16 months now and I have used it multiple nights during the winter. It works really well, but can be a bit finicky to get started. I usually have to hit the reset button on it and I am glad it is not installed outside and I can get to it. After using this setup quite a few times I think I would change where I have the vents and put them lower. I also use a piece of the ducting to focus the hot air in different directions, this is really nice on single digit nights.
 
I just installed a 3.5 Fuelpax and mounting plate from Rotopax. I removed the wall on the inside to see where the frame was and taped it off on the outside. Before I bought it I made templates to make sure it would fit. I ended up having to use aluminum bar as a spacer so the can wouldn't rub the jack plate bolt. Overall, I'm very pleased with it and it's nice to have this extra "insurance" when going out.
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Reading through your thread again as we consider building out our shell or just finding another Eagle with factory options. Nice work on those cabinets! I think not having the factory propane storage cabinet, or option to add one is a big reason we are thinking about getting another Eagle. Our rollover is on the driver's side, so not an option....unless we reverse that. Any updates? Thanks!
 

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