The Half-arsed Camper build

[Reddave]

Firstly, apologies if this is in the wrong spot.

Secondly, I will just be copying and pasting from another forum I'm on

Back in may, I had to decide what I was going to do with my camper.

Here's what I started with:
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/5b10d2a6.jpg

Paid $1200 off eBay about 12 months ago, I knew when I bought it that it needed a bit of work, had no rego, brakes, canvas was old, but it was solid.

We have used it about 6 times over the last 12 months and the time to start making decisions got closer and closer.

I considered just selling it, making my money back and replacing it with another trailer, but the tight arse came out in me!!!

If I rebuild the trailer and add a new camper top, brakes and rego, I get a trailer that is made just for us, and should owe us no more than $5,000 when completed.

Cut off the old box the sides were only 280mm high, useless for storage.

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/4eb01db1.jpg

[Reddave]

Once I got my tax return in July, I went on a bit of a spending spree

6 Stud electric brake backing plates and drums
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/70003356.jpg

45mm square axle with brake mounting plates welded, rated to 1500kg, same track as the GU (1676mm)
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/e437ff99.jpg

Drop down ALKO style stabiliser legs
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/63da652c.jpg

7 leaf Off road springs, 60mm wide, eye to eye
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/c312750c.jpg

Assorted bearings, wheel nuts, shackles and hangers, spring plates and U bolts
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/84b15b6a.jpg

Just need to get my new floor steel, fit all this stuff then I can work out the final height that I need for the sides for a tent drop of somewhere between 1000mm and 1200mm

Got all this stuff direct from a trailer spares place that advertises on eBay, eBay price for springs, axle and brakes $670.00 plus postage.

Rang them direct, asked for a good deal, all the above for $633.00 (so $40.00 off eBay price and free stabiliser legs)


Rang CARAC today and ordered my sides and tailgate, could be up to a 2 week wait, if I knew that I would have ordered them 2 weeks ago :(

Ordered my steel for the trailer floor

Bought some canvas, only a cheap canvas but will do for a couple of years :D
http://www.enztrading.com.au/products/Ezytrail-campers-23x18ft-14oz-ripstop-canvas-tent-.html


http://i124.photobucket.com/albums/p30/reddavehasbeentaken/ccc2__69230_zoom.jpg

[Reddave]

Didnt get as much done today as I would have liked, but still some forward progress at least

Cleaned up all of the frame from where I cut off the old box, cut off the old stabilisers, wire brushed the drawbar and frame
Assembled my axle, packed the new bearings, set bearing preload, marked the position of my spring centre pin spacers, marked the position of the front and rear spring hangers.

Won the tent we were bidding on, it's a steal for $1299, just have to work out how I am going to pick it up now, my trailer is in pieces :(

Mels Mum and Dad went away for the weekend so no welding :(

Next weekend should be when the transformation starts

Trailer floor is here, once I get my sides that can all be tacked together

The to do list as of now is:
Cut off the old spring hangers
Weld new spring hangers
Assemble floor and sides
Fit tent
Then the mudguards, light boxes etc

Costs so far:
Springs, axle, electric brakes, stabiliser legs $633
Sides and tailgates $280
Camper tent $1299

Total so far: $2212

So far running under budget :)

[Reddave]

August 10th


Went on another spending spree today :)

Bought taillights, 110mm round, same as the XTRAIL Navigator

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/ranger_side_rear_l.jpg

Picked up Tailgates and sides, Offroad chequer plate mudguards, Jerry can holders x2, Gas bottle holder x1, Alko Offroad coupling, Handbrake assembly, Water tank, hand pump and filler.

And put a 40lt Engel on layby (Ran out of money for that one)

The building should hopefully start this weekend, we will be adding a foot to the end of the trailer, mounting the springs and axle and then seeing how much time is left :D

Hopefully fit up the floor and at least tack the sides and tailgate on as well.

So to recap cost:

Springs, axle, electric brakes, stabiliser legs $633
Sides and tailgates $280
Camper tent $1299
Offroad Coupling and Handbrake $290
Jerry can holders and gas bottle holder $75
Water tank, filler and hand pump $184
Mudguards $115
Taillights $99
Misc Steel $35

Total so far: $3010

So far running under budget, but its starting to blow out :(

[Reddave]

August 12th

Started putting it all together today, got a fair bit achieved, I'll let the pics do the talking!!

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/07c707db.jpg
Added a foot to the end of the box

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/01c39b31.jpg

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/3535cfc5.jpg
Set up the leaves and shackle mounts

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/9991321d.jpg
Started fitting the sides and squaring it up

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/426298cd.jpg
Fitted the front tailgate, this will be fixed in place

we used steel lengths to tie in the sides and for the tiebar for the front tailgate

The shackle mounts and spring mounts are completed, put the locating plates on the axle, but will not be fitting the axle until we weld the floor in, it's too heavy to flip on its end :)

The sides and front tailgate are only tacked at the moment, they will be welded during the week

Next week, need to trim the floor piece and then tack it in place, then flip it and start the long task of sealing the floor without warping the steel :(

[Reddave]

August 18th


http://i124.photobucket.com/albums/p30/reddavehasbeentaken/8029D70E-E134-4D42-8B03-A3520F699012-13677-0000125C40211E76.jpg
Floor all welded in, had a small bow in it, but clamps and a trolley jack got them all out :)

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/77B1028B-05CE-49C3-828F-9EFF2911507A-13677-0000125C4C334920.jpg
Welded in the brackets to mount the water tank, decided on mounting it just behind the axle, once I get the toolbox on the front and kitchen in the back, it shouldn't have too much weight over the front

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/3DEA2163-54CA-44A6-9930-04570B14122D-13677-0000125C5EA1FE8B.jpg
Welded in the brackets to take the stabilizer legs

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/C167BE0C-518D-46F2-A2DB-BF4CFA7EFDCE-13677-0000125C6D9CD1F0.jpg
Welded up the sides to seal the floor completely

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/77303BA8-5900-414B-9924-BF80AA7984EE-13677-0000125C7A0A59ED.jpg
Then fitted the axle to position the mudguards, farkin location plates were 6mm out, cut them off, remeasure and start again :( also have to run spacers on the hubs, they sit too close to the springs :(

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/58017D55-A44D-4361-B538-174D31EC5C09-13677-0000125C85A0263B.jpg
And the other side :)

The plate on top of the box we will not be using, it measures at 1120mm from the ground to the top of the box, ideal height :D

Tomorrow it's time to add the side panels, mount gas bottle and jerry can holders, finish off the tailgate, make light boxes, run all the strapping and then get a start on cutting down the drawbar and mounting the hitch

My list is slowly getting smaller, but still have to paint, run wiring, gas lines, power and battery box, tool box etc etc

[Reddave]

August 19th


http://i124.photobucket.com/albums/p30/reddavehasbeentaken/0E8488B9-E8F4-4F97-87BF-4162DEF81B93-14262-000013642A161914.jpg
Added the end plates

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/46072228-6C31-48D8-94D9-87B3D5568C5D-14262-000013643EF9CD7C.jpg
Added the sides, the end plates and side panels all have 50mm strapping to add more strength

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/AD05295C-B63B-4DBE-8D7D-F8824F932B31-14262-000013644B7252FB.jpg
Added the taillight boxes, now have to drill holes in them to fit taillights :(

Got most of the welding completed today, only the jerrycan holders, gas bottle holder, spare wheel mount, toolbox left to weld, then about 2 days grinding and prepping for paint, then its time to add the hitch and handbrake, wire and paint

[Reddave]

August 26th

Got the holes drilled for the taillights yesterday, fitted the jerry can holders, gas bottle holders and hung the tailgate

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/1E14D91B-85B0-4E45-9F11-98CF2CFC9C35-19623-00001AB3C5C42421.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/436296FA-DF59-459D-B31F-AB189D7A6F5D-19623-00001AB3B86CDF56.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/3C3F1F8A-8C07-4989-A23C-B31165D45298-19623-00001AB3AB4DC578.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/C365C6F9-26C5-4722-9168-FB4CC667DF04-19623-00001AB39D904E77.jpg

[Reddave]

September 8th

It has a top on it, and it folds out the way it should!!!

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/CFE37268-17CB-4FA5-8A1C-F2518CD81BC3-30820-00002935CE0B7AFD.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/7ECD36A3-D4DE-4A4C-BF19-DC90A50C8098-30820-00002935EA2511AE.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/16E47F27-11B1-4065-94BA-551ACF2069D7-30820-0000293600442F56.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/29E77D27-73B0-4577-91D7-FA54FC20D060-30820-000029361FA551FD.jpg

[Reddave]

September 16th

Got a bit achieved yesterday after work, all of the welding is complete!!!

Got the water filler plate welded in, thanks Matt (or Geoff) for cutting the hole out for me

Fitted up the struts to the bedbase
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/845ACD21-F73E-4089-BFEA-6E7D56EBCD0B-1356-0000016FA69C06EC.jpg

Made up the hitch plate and trial fitted the hitch so I didn't have to weld it to the back of the car
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/FAD7FF9F-4A85-486A-B1F9-7C4FA683CD65-1356-0000016F99D72103.jpg

Pulled the bedbase back off, started grinding and then picked it up and flipped it over so we can seal the floor and start painting and wire it up. It's bloody heavy!!!

Need to get some paint during the week!!!

[Reddave]

October 8th

Spent a bit of time with the family over the school holidays, wanted to go away but the camper was upside down with no paint on it!!!!

Still managed to get away, just cost a lot more :)

Picked up my etch primer and paint today, using a hammertone dark charcoal, almost black in colour. Hopefully at least lay some primer on over the weekend.

October 13th


Layer down some primer today, did my first time painting, think it came up pretty well!!
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/497D8DCF-F986-444B-8C83-47F11757BE4E-7828-000008FB27B21982.jpg

[Reddave]

October 14th

Layer my color on the bottom this morning

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/04081093-9E7F-44FD-83FA-4240F723925A-8800-000009FE98C141E8.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/5AA9CDC5-2A1C-41A4-B309-AAC8F8159DCB-8800-000009FEA9BF7685.jpg

Then flipped her over and primed the top, then ran one coat of top coat. The bad news is that if I didn't paint the second coat within 2 hours then I have to wait 48 hours to paint a second coat :(

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/DDF8FF30-E846-427B-9A03-D7B22FC0ACA5-8800-000009FEB88CF180.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/4A969521-401D-4456-B775-5C17CC440D02-8800-000009FEC77B0289.jpg

The good news is its almost done!!!

Once the painting is all done, then I'll take it to work to do the wiring and plumbing for the water tank. Then it's time to take it over a weigh bridge and book it into vicroads for rego!!!

[Reddave]

Lets recap cost
Costs so far:

Springs, axle, electric brakes, stabiliser legs $633
Sides and tailgates $280
Camper tent $1299
Offroad Coupling and Handbrake $290
Jerry can holders and gas bottle holder $75
Water tank, filler and hand pump $184
Mudguards $115
Taillights $99
Misc Steel $100
Cutting discs, grinding discs $26
Varnish and brushes $30
VIN plate, tailgate catches and lock $30

Total so far: $3171 plus:

Paint and thinners: $220
Reflectors: $25
Wheel spacers: $50
Flap discs and sealer: $70
Other misc crap: $150

Total so far: $3686

Plus the cost of the camper $1200 brings it to just shy of $5,000


Budgets been blown out of the water, still have about $1000 worth of wiring to do :(
It's what ever it costs now, but that's how it goes!!!

You couldn't buy one like it for the price

[Reddave]

October 15th

Ordered an ARK powerpack today
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/ARK_POWER_PACK_4a7b616d037de.jpg

Simple way to get a battery and a heap of outlets into the camper using only anderson plug wiring. If I need to run 240 volt in the future then I can always put an inverter on this setup.

October 16th

Went and had a look at the camper today (it's at Mels mum and dads)

Mels dad has put the final coat of paint on, looks a treat!!! I don't have pics at the moment, didn't bring my phone inside :)

Just have to get some bolts tomorrow to mount the toolbox and kitchen, mount the hitch and handbrake lever. Then I get to tow it for the first time!!!

To work so I can wire it and finish the handbrake, mount the water tank and plumb that

[Reddave]

October 18th

It's reveal time, wheeled it out of the shed today.

Need to finish wiring and plumbing, mount handbrake and the camper top once I get some rubber to seal the tailgate and top.

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/EAF61B88-B10C-44EE-8600-F33DA6A1EF0B-12988-00000E6E48F40D0B.jpg
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/3960B412-9EB5-48B5-96E7-5FAAD3FFE16F-12988-00000E6E56DF83AC.jpg

October 19th


It went in its maiden run today, from Beaconsfield to wantirna :)

Tows and tracks quite well and it's quiet on the road!!!

Fitted the reflectors, handbrake lever, stabiliser legs and wheel spacers and centre caps. Looks trick with Nissan centre caps :)
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/1B670219-4DCC-4ABC-A0AE-6594F0C835DF-13942-00000F839EF37F27.jpg

Have a list as long as my arm of little bits and pieces that I need to pick up over the weekend to start wiring, plumbing and mounting more stuff

[Reddave]

October 25th

Today finished all of my wiring, for the lights anyway!!!

Mounted my water tank, just need to plumb it up now
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/A811BE08-9CC9-4034-B2D8-47FAE18DD4FD-18930-000016392E9DC49D.jpg

Fitted dust seals to the camper top and also the tailgate:
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/1CDEEA44-4B42-4C8E-9476-FA5901ECB576-18930-000016391D7A97D9.jpg

And fitted my ARK Power pack, just need to get a battery and wire that via an anderson plug to the Patrol
http://i124.photobucket.com/albums/p30/reddavehasbeentaken/0E33AFA8-F2ED-4830-ADF1-8A38F1D12D7F-18930-000016390EB003D8.jpg

Then its ready for its weighbridge certificate and then rego!!!!

[Reddave]

October 26th

Started plumbing my water tank today, got the breather line fitted, but need to get some right angle joiners to do the fill and supply lines!!

I'm taking it home tonight so I can fit the top and get it weighed tomorrow, then finish the water tank and set the thing up in my backyard to weather the canvas over the weekend

October 27th

It's weighed, 540kg without the canvas on it and the water tank empty.

The axle is rated to 1400kg, so pretty happy with the weight

October 28th

Kitchen is all done:

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/5ED830E8-6D8F-4A5E-8C2F-EA9F1D081F2D-1974-0000023DADF4D680.jpg

My $60 kitchen has turned into a $360 kitchen after spending $300 on storage solutions from Bunnings :D

But that also included some massive 120 litre tubs for inside the trailer

[Reddave]

October 31st

And now it has rego!!!!

Going up to Kurth Kiln for a night on saturday for the first of its shakedown runs :)

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/2A0A59A4-626D-4A59-9FD7-14FDC2FA03EF-5249-000005A6C1509DA6.jpg

Safety first!!!! (So I can cook)

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/EE13F465-CC38-4F18-852C-0224E692493E-5249-000005B5E1370FC8.jpg

Next to the fire extinguisher I have mounted an engel plug so we can leave it plugged in under the kitchen!!!

[Reddave]

November 4th

Got home this arvo from staying at Kurth Kiln, the joint was packed, had to get all the way in the back corner to have enough room!!!

http://i124.photobucket.com/albums/p30/reddavehasbeentaken/4D3E252E-F65F-4C99-A5D2-10A917C8816C-1988-000001E5BAABB12D.jpg

Now have a list of things to do with the camper:
Needs LED lighting
The Matress sucks balls (not literally, I wouldn't change it if it could do things like that)
Need to fit a tap/one way valve on the water tank line, sick of the kids playing with it!!!

But it went up and down a treat, sits almost perfectly level on the car so don't even have to unhitch!!!

[Reddave]

November 18th

Well second time out in the camper, have a few "bugs" to iron out

1) still need to sort out another Matress, the one that we took off our bed fits, but we can't close up the camper
2) still have to wire it properly for Anderson plugs and 12v power
3) the corrugations coming up through Woods Point have shook the water tank out of its mounts

Better to find out about the corrugations/water tank now :)

I wasn't happy with the way I had mounted the tank anyway, this just speeds the process up!!!

4) have to go over all the bolts and retension them to make sure they are all Ok
5) will have to have a look at bigger tool boxes for the drawbar, it doesn't matter how much crap you have, you always take more :D
6) really need to get a stone guard on the front, it got hammered coming up to Skipworth
(Or I could put mudflaps on the GU)

[Reddave]

So that's where it sits as of now, and still have a list as long as my arm.

Sorry for the amount of photos, but you don't understand how much is actually involved until you start doing something like this.

If you have any questions, don't hesitate to ask.

A big thanks for Mel,( my girlfriend) for putting up with me while I built it

And thanks to Mels Dad who helped me and kept me motivated the whole time, there was many times I was ready to sell it and walk away

[Reddave]

And for the record totals were just under $6,000 as it sits, so just over budget, but it didn't blow out too much

[Clunk]

great read mate, looking forward to seeing how it progresses

[Rip'n'Shred]

Well done mate. Most would have given up. Big job but the results look worth while.

[Reddave]

Thanks for the comments, it was worth it in the end

Jut a few things to tidy up and then I'll be happy with it :)

[89gqpatrol4x4]

wow! big job but the results speak for themselves. A fully customised camper for around $5000 not bad.

[NissanGQ4.2]

Great build mate, very nicely done

Have moved your thread over to the DIY Section under "OTHER" because I think it would be a great read for anyone thinking about doing there own camping trailer

Cheers

Todd

[threedogs]

You've put so much work into it why not get the lot Gal dipped??
Good work by the way. Just finished a single cab hilux camper.
Did you use a triple 180mm draw bar??

[Reddave]

You've put so much work into it why not get the lot Gal dipped??
Good work by the way. Just finished a single cab hilux camper.
Did you use a triple 180mm draw bar??

Main reason for not gal dipping was cost and the time constraints I was under
There's always next time lol (do things ever only get built once)

The drawbar is off the original trailer that I cut up, I'm not sure of length, but with my toolbox on I can still open the swingaways and get into the back of the patrol on an angle.

[Woof]

Great job there mate, thanks for sharing it with us.

[megatexture]

top read mate looks good also!, another thing could add if you have trouble with the kitchen draws opening during transit is some Velcro(pop rivit and sikaflex on) around the kitchen and some shade cloth with Velcro sewn on it, works a treat for mine and keeps it all in and weighs nothing pulls off once your at camp in 2 seconds and seconds to put back on. i can get a pic if you like just hard to describe

thanks for sharing

[Reddave]

top read mate looks good also!, another thing could add if you have trouble with the kitchen draws opening during transit is some Velcro(pop rivit and sikaflex on) around the kitchen and some shade cloth with Velcro sewn on it, works a treat for mine and keeps it all in and weighs nothing pulls off once your at camp in 2 seconds and seconds to put back on. i can get a pic if you like just hard to describe

thanks for sharing

Thanks, at the moment I use the storage tubs and pack the trailer quite tight so the drawers are unable to move

[Bloodyaussie]

Lovely jubbly , now you can start on mine..err... you do know I pay in loves!!!!!

He he!!