Keystone Rebuild - Narrow Floor Pack, Redo Interior, Paint Exterior

Well, I got to work on the camper a little bit the past couple days.

First, since I was going to put a new floor in it, I took out the 3/16" ply that was glued down to the floor from the factory. I did this because the ply didn't cover the whole floor, so there was no ply where the built ins used to be. The ply was glued and stapled down, so it took some work to remove all the pieces. I had to sand the last little bit of glue/ply pieces off with a DA.

I then mixed up some epoxy and epoxied all the interior wood. Most all this will be covered when I am through, but I thought it would be a good idea to seal all the wood on this camper when I had the chance.



I went to Lowes today and bought some cheap laminate planks. I've used this same stuff in my shop's office and it has held up great with all the traffic and sand/gravel that gets tracked through there. It has a 40 year warrenty (if that means anything ;)). After the epoxy was dry, I started to lay down the laminate. It was a quick process and looks MUCH better than that old linolium that was on there before.





After the floor was down, I got out my soldering iron, wire and connector box and went to work rewiring the whole back end. I wired in the tail lights, porch light and backup lights. I wired the backup lights so that they could be either activated in the truck (when backing up) or activated by a switch inside the camper. I thought I might as well have access to bright floodlights in the camper if I need them for any reason.

Soldering them up




And finished



Before I put the 7 pin plug on the end of the wire loom, I tested it out to see if everything worked like it should. It did.




I spend the remainder of the day starting in on insulating the back of the camper with 1" XPS foam. Depending on the weather tomorrow (if it is raining, I can't sandblast outside), I might get the remainder of the camper all wired up and insulated, then start in on the beadboard paneling.

Its coming together!
 
Thanks guys!


Time for another update. Didn't do too much, but it is slowly coming along.

Started insulating with 1" XPS foam. It has an R value of 5, so it is twice as insulating than the fiberglass matt used in the original.



Then I started cutting the Birch ply and installing it.





I was then able to install the back lift panel, so I had to preload the spring hinges before installing it.



After installing the back lift panel, I installed the insulation on the front and passenger side walls, then installed the birch ply.







I'm not sure that I really like the color of the paneling, the camper feels like it has a little too much yellow in it with the paneling installed. I'll probably finish the build, install the cabinets, etc, then see how I like it.

I really wanted to have it look brighter, more modern inside. I might paint it after the build is done.

Lastly, I installed a new water filler setup. The old one was very deteriorated, almost foamy looking. It should be easier to fill with this new design as well.



That's it for now. I might work on it a little over the weekend. I'm itching to go up in the mountains, though its supposed to rain all weekend.

I just might head to the high country for some snowshoing,
 
Great project. Enjoy watching. What did you use to attach your paneling? I need to find something that works well for my little project. Nice job. Mitch
 
Thanks guys. W.S. I think I'll finish the build first, and if I don't like the color, I think I'll caulk paint the paneling a cream color. Caulk painting looks almost like a pickling, but is done with a caulk based paint and either clear, or dark wax rub.

Mitch, I used 1/4" crown 3/4" long staples and a pnumatic stapler. That is how they installed the paneling from the factory so I figured it should be good enough for me :).

The staples go right into the aluminum and are VERY difficult to remove.
 
I did a little more work to the camper.

First, I finished up installing the rest of the insulation and paneling.

Now comes the fun part, designing and building the interior. I measured the interior of the camper carefully and built a model in Illustrator. I then designed the cabinetry and seating arrangements that would work best for what I want. It is very easy to design exactly what you want when you make a model this way, as long as you take careful measurements and make the model correctly. You can see right away what type of clearances you have or if something interferes with something else.

After I had the plan made I started cutting the cabinet face using some cabinet grade ply. I then installed it in the camper so that I could measure some of the other pieces I needed to make.



Installed the sides and counter top supports.



I then cut out the counter top pieces and installed them. Here's a photo when I was testing the fit of the components. I am using the old stove and sink that came with the camper for now. I'll probably buy one of those european style sink/stove hobs in the future as they are really space saving. It would be easy to install, just build a new counter top.



The cabinetry will be primed and painted an off white or very light grey. I think I'm going to use some bedliner for the countertops as it is very durable, waterproof and looks pretty decent if done right. If I don't like the look, I'll sand it down and finish it with an epoxy/chip then clear coat. I think I'll like the bedliner though.

Next up, building the seating and table. I am going with a front dinette seating with a narrower couch on the side. Both the couch and dinette will convert to beds, so along with the double bed up top, the camper should be able to sleep 4 comfortably.
 
Just had the chance to check your rebuild.
Very nice work. I like the looks of the interior.
The floor really makes the job,IMO. I also used some leftover laminate
on mine and it makes the interior look like nice.
Keep up the nice work.
Frank
 
thanks for the reply. I don,t have to attach any thing to the walls. I am just putting in storage off the floor pack. Probly just us a glue for the finish paneling. Your rebuild is coming along great. Enjoy. Mitch
 
Thanks Guys!


I did some more work to the camper the past couple of days.

First, I finished up the cabinet area that covers the water tank and heater. I then sprayed bedliner on the counter top and on top of the area where the Engel Fridge will sit.



I then built the seat bases using some 3/4" ply. I stayed with what I planned for the layout. So, I'll have a dinette area at the front of the camper and a bench seat down the passenger side. Both will turn into beds if I need the extra sleeping area.



I then built the slide out bed portion of the cabover. I used 3/4" Birch ply for the bed itself and faced the front with a 1" x 3" oak plank to strengthen up the front area so it won't bend over time.

I used 1" x 3" Poplar to make the side supports and screwed them into the aluminum frame. It works great and I now have a double sized bed when it is slid out.

Retracted.



And slide out.



I still have a lot of work to do, but it is really starting to feel like a camper!

Next on the list is to make a drawer and the cabinet doors. I also need to cut out some ply for the bottom of all the cushions. I think I can talk my Mom into sewing all the cushion covers (hopefully!). Then I'll sand down and paint all the cabinets and seat bases.

After all that is done, the inside will be near complete and I can work on filling all the little dings to the outside and painting it.

Getting closer and closer to completing this build. Can't wait to get it finished and set on my truck for some camping!

 
Andrew, very cool! I'm going to move the photos post over to the landscape thread, right after I apologize for taking us off topic. Wonderful photography!

Edit: Well, I will right after I figure out how to do it... :unsure: OK, I found part of it, and MarkBC gave me the missing information. Post moved to Landscape.

Thanks Mark!!
 
Yeah, really nice project! Looking forward to seeing the next steps and the finished product (as I know you are too).
 
Fantastic work. Can't wait to see the final result. A lot of you guys have some serious fabrication skills
 
Colorado, I've really enjoyed your post of your build. As you can tell I am a newbie to All this. I stumbled across a 1983 FWC Keystone the middle of April and have picked up a ton of information to allow me to narrow the floor pack , rebuild lift panels and more. Can't wait to see your final results. It is looking great. Keep up the great work!
 
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