Westy's Jayco Dove Build

[BigRAWesty]

So many would have seen pics here and there of this van Ive been doing up.
Yea this is the build thread lol.
Ok start from the beginning..
When we bought it it was professionally lifted and on 31's..
But only after handing over the hard erned and getting it home ive started really noticing that it was anything but professional..
The lift was done with 2 piss ant bits of steel and if it ever got air it would come apart..
Dont even start on the 10" hilux hubs on 9" backing plates..
And the POS spare wheel mount made for the back..
http://www.nissanpatrol.com.au/forums/images/imported/2017/04/333.jpg

[BigRAWesty]

So first up was the chassis..
Took the old drawbar off and made a full length new chassis.
Lengthed it by 800mm so i can add a toolbox.
Also added stability legs..
http://www.nissanpatrol.com.au/forums/images/imported/2017/04/334.jpg
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/2017-01/tapatalk_1483349353646_zpswrzbctkm.jpeg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/2017-01/tapatalk_1483349353646_zpswrzbctkm.jpeg.html)
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/2017-01/20170105_172214_zpsofb7rm7m.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/2017-01/20170105_172214_zpsofb7rm7m.jpg.html)
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/2017-01/20170105_172351_zpscbtuepjq.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/2017-01/20170105_172351_zpscbtuepjq.jpg.html)
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/2017-01/20170105_172337_zps09fkela1.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/2017-01/20170105_172337_zps09fkela1.jpg.html)

[BigRAWesty]

Also added new suspension, lengthed the drawbar, added a 50mm axle and 10" brakes.
She then sat much nicer..
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/2017-01/tapatalk_1483349361889_zpsblpdq5wn.jpeg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/2017-01/tapatalk_1483349361889_zpsblpdq5wn.jpeg.html)

Anyway then started the rear bar.
Had to cut the ass end off..
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/2016-10/20161013_114702_zps8fsk5o2l.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/2016-10/20161013_114702_zps8fsk5o2l.jpg.html)

Then paint..
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/20170115_203023_zpsay7bga4m.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/20170115_203023_zpsay7bga4m.jpg.html)

Unfortunately found some root in the front so rebuilt it..
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/20170110_174520_zpsqv28frmj.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/20170110_174520_zpsqv28frmj.jpg.html)
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/20170114_171850_zpsey1kbyn9.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/20170114_171850_zpsey1kbyn9.jpg.html)

http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/20170126_160316_zpsvg6zviec.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/20170126_160316_zpsvg6zviec.jpg.html)

And then inside..
http://www.nissanpatrol.com.au/forums/images/imported/2017/04/335.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/04/336.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/04/337.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/04/338.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/04/339.jpg

[BigRAWesty]

And now were on 17" rims
http://www.nissanpatrol.com.au/forums/images/imported/2017/04/340.jpg

[BigRAWesty]

So now its onto some 12v..
Battery and basic setup done.
Got a few chargers in, 12v lights now in roof and going to mount pump in to..http://www.nissanpatrol.com.au/forums/images/imported/2017/04/341.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/04/342.jpg

We did the stove up with hi temp paint
http://www.nissanpatrol.com.au/forums/images/imported/2017/04/343.jpg
http://i1272.photobucket.com/albums/y387/BigGQWesty/Mobile%20Uploads/20170327_201609_zpsf14akkho.jpg (http://s1272.photobucket.com/user/BigGQWesty/media/Mobile%20Uploads/20170327_201609_zpsf14akkho.jpg.html)

Made new sear covers
http://www.nissanpatrol.com.au/forums/images/imported/2017/04/344.jpg

Have also added a second water tank so now twin 60L
http://www.nissanpatrol.com.au/forums/images/imported/2017/04/345.jpg
http://www.nissanpatrol.com.au/forums/images/imported/2017/04/346.jpg

[TPC]

Very impressed with what you have done there mate. so when we get ours I can bring it to you to be kitted up. ;)

[Patrol'n]

Looking very good Kallen, that's the same type of camper I've been considering.

[BigRAWesty]

Very impressed with what you have done there mate. so when we get ours I can bring it to you to be kitted up. ;)
I have enjoyed it so far. It really isnt to difficult either..

[mudnut]

This build is awesome, Kallen. What are the springs rated at? You will need to heat that paint on the stove for a while before you use, or the fumes will be horrendous. We were caught out with our new wood heater. We heated it for ages, but one night we stacked it chockers full of small stuff and it got hotter than normal. The stink drove us out of our house.

[BigRAWesty]

This build is awesome, Kallen. What are the springs rated at? You will need to heat that paint on the stove for a while before you use, or the fumes will be horrendous. We were caught out with our new wood heater. We heated it for ages, but one night we stacked it chockers full of small stuff and it got hotter than normal. The stink drove us out of our house.
Its actually engine block paint.
So no baking required and no fumes when heated.
Good for 500c from memory.

I originally bought 1.5t spring set. But after a few trips and over the scales ive worked out its only going to be 1.3t max.
So have removed 2 leafs each side and its much softer which is good.
Didnt loose any height but will when loaded.
I have a lot of wheel arch left so not to worried about a bit of sag..

[BigRAWesty]

So we now have lights..
All 3 draw about an amp..
Dont mind the patches.. the roof is being done after our trip..
Its not bright but is a nice warm white..
I used the crappy old 240v cable to pull through the 12v wire.
Each light has its own switch, but has a master switch just behind the sink.

You can also see the 12v outlets to the right of the stove. Simple cig socket and usb outlets with voltage gauge..http://www.nissanpatrol.com.au/forums/images/imported/2017/04/350.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/04/351.jpg

[mudnut]

With the softer springs it will feel a lot better behind the tow vehicle too. Must do the same to my trailer as it is a bit harsh. I have shown this thread to Mrs mudsane and she likes the idea of buying cheap and upgrading the van.

[BigRAWesty]

With the softer springs it will feel a lot better behind the tow vehicle too. Must do the same to my trailer as it is a bit harsh. I have shown this thread to Mrs mudsane and she likes the idea of buying cheap and upgrading the van.
Well the 1.5t leafs had no give. It was all un the tyres..
So only ran 30psi..
Now the 32's are at 40 and its softer still..
Probably should fit shocks but agaun not something tha is critical before we leave..

[Rossco]

Looks awsome kallen, do love my dove they are a good little unit. Did you make the chassis or buy it as a kit, do like the idea of a full new chassis. Same with mine had some rot in the back but luckily was contained, used a heap of silicon to try keep it dry. Was also worried about it being too harsh with new springs but isn't too bad actually.

Sent from my SM-T800 using Tapatalk

[Cuppa]

Home away from home!

A couple of things you may want to do to your water supply to save yourself possible grief somewhere out in the never never though..... based on personal experience.

I've used those black tanks suspended by metal straps as you have & suggest that you insert a sheet of ply or similar under each tank. The tanks are fine suspended like that on bitumen, but if suspended with just the straps on corrugated roads they will leak sooner or later. The weight of the water constantly pushes the bottom of the tank up & down & eventually they develop a leak in the middle of one end - a result of the plastic fatiguing. You would be most unlikely to have this happen during your forthcoming trip, but if you do enough corrugated kilometres it will happen eventually, & the chances of it happening when it's convenient are slim. Been there done that! Putting in a ply panel adds extra support under the entire tank & solves the problem, as well as protecting against damage from flying rocks.

I would also add some sort of protection to the water hose which may be damaged by flying rocks to save the possibility of pulling up for the night & finding you have lost your water. Assuming you have the two tanks connected it would be a good idea to have a tap between them if you haven't already done so. That way if one tank loses water you wont have lost it all if the tap is shut at the time. The new tank has drinking water hose on it, but the original doesn't. IF you get unwanted 'flavour' changing to all drinking water hose will help.

And one other thing which I'm confident you will have done, but I'm mentioning it for anyone else reading who might not think of it - use high tensile bolts to do up those tank retaining straps.
We lost all the water from one of our two tanks out in the WA goldfields, caused by 'corrugation fatigue & which cut short our time there as we had to go back to Perth to get a replacement tank (after numerous attempts at repairs had failed in Kalgoorlie). When I fitted a new tank (together with ply support sheets) I used standard bolts. They lasted for about 3 years until they let go whilst we were on a weekend away. This was in the bus & I was alerted by the sound of the 'north/south' metal straps scraping on the bitumen road & managed to pull up before the tank was damaged. Roadside repair meant draining the full tank & a LOT of hassle. Luckily we were not too far fom home. In a camper trailer chances are you wouldn't notice anything amiss until you pulled up somewhere.

Paint job looks better than the original & gives the whole shebang some individuality (& suits the Patrol nicely).

[Winnie]

Very nice westy. Love the little Jaycos and you've done real well with yours.

Sent from my SM-G935F using Tapatalk

[Maxhead]

Nice job Westy,I agree with Cupps, protect your water!
We had small leaks in some plastic hose elboews and front tap on the draw bar, all because of rocks. We had a rock tamer on the back of the Patrol but it did not stop tocks from hammering everything underneath.

I ended up puting shit loads of layers of electrical tape to protect the plastic elbows after I fixed them was a lighter and a screwdriver to close the cracks.

Metal ones for a win









...........on the road

[BigRAWesty]

Home away from home!

A couple of things you may want to do to your water supply to save yourself possible grief somewhere out in the never never though..... based on personal experience.

I've used those black tanks suspended by metal straps as you have & suggest that you insert a sheet of ply or similar under each tank. The tanks are fine suspended like that on bitumen, but if suspended with just the straps on corrugated roads they will leak sooner or later. The weight of the water constantly pushes the bottom of the tank up & down & eventually they develop a leak in the middle of one end - a result of the plastic fatiguing. You would be most unlikely to have this happen during your forthcoming trip, but if you do enough corrugated kilometres it will happen eventually, & the chances of it happening when it's convenient are slim. Been there done that! Putting in a ply panel adds extra support under the entire tank & solves the problem, as well as protecting against damage from flying rocks.

I would also add some sort of protection to the water hose which may be damaged by flying rocks to save the possibility of pulling up for the night & finding you have lost your water. Assuming you have the two tanks connected it would be a good idea to have a tap between them if you haven't already done so. That way if one tank loses water you wont have lost it all if the tap is shut at the time. The new tank has drinking water hose on it, but the original doesn't. IF you get unwanted 'flavour' changing to all drinking water hose will help.

And one other thing which I'm confident you will have done, but I'm mentioning it for anyone else reading who might not think of it - use high tensile bolts to do up those tank retaining straps.
We lost all the water from one of our two tanks out in the WA goldfields, caused by 'corrugation fatigue & which cut short our time there as we had to go back to Perth to get a replacement tank (after numerous attempts at repairs had failed in Kalgoorlie). When I fitted a new tank (together with ply support sheets) I used standard bolts. They lasted for about 3 years until they let go whilst we were on a weekend away. This was in the bus & I was alerted by the sound of the 'north/south' metal straps scraping on the bitumen road & managed to pull up before the tank was damaged. Roadside repair meant draining the full tank & a LOT of hassle. Luckily we were not too far fom home. In a camper trailer chances are you wouldn't notice anything amiss until you pulled up somewhere.

Paint job looks better than the original & gives the whole shebang some individuality (& suits the Patrol nicely).

Hey Cuppa.
Yea i love the colour. Funny thing though its the old gq colours flipped lol..

But i do have sheet metal gaurds made up which span nearly the width of the chassis, so tanks and all hoses are protected.

And yea i have taps on the out lines. Each tank has a seperate fill point.
And yea all high tensile bolts across the build.


Nice job Westy,I agree with Cupps, protect your water!
We had small leaks in some plastic hose elboews and front tap on the draw bar, all because of rocks. We had a rock tamer on the back of the Patrol but it did not stop tocks from hammering everything underneath.

I ended up puting shit loads of layers of electrical tape to protect the plastic elbows after I fixed them was a lighter and a screwdriver to close the cracks.

Metal ones for a win









...........on the road




Looks awsome kallen, do love my dove they are a good little unit. Did you make the chassis or buy it as a kit, do like the idea of a full new chassis. Same with mine had some rot in the back but luckily was contained, used a heap of silicon to try keep it dry. Was also worried about it being too harsh with new springs but isn't too bad actually.

Sent from my SM-T800 using Tapatalk

Yea mate made the full length chassis myself.
And the rear bar.
Dual wheel carrier and tripple jerry can holder..http://www.nissanpatrol.com.au/forums/images/imported/2017/04/355.jpg

[Plasnart]

I've got one word for you Westy: Love it! :D

Absolutely fantastic job mate. :smiley_thumbs_up:

[Clunk]

I've got one word for you Westy: Love it! :D

Absolutely fantastic job mate. :smiley_thumbs_up:
That's 6 words and some emojis

[MudRunnerTD]

Looks Awesome Kallen, Credit to you mate.

I think you missed what Cuppa said about the ply. He was not suggesting it as a stone guard but rather fit the ply on top of the straps and the tank on top of the ply being the ply will spread the load and the straps won't eat into the tanks when full of water. I agree with Cuppa. Stone guard will help protect from punctures though for sure.

Great job mate! That chassis looks great. Do you know a good Welder.....

[Plasnart]

That's 6 words and some emojis

Derr Fred! Thought you especially would get subtle humour! :)

[BigRAWesty]

Looks Awesome Kallen, Credit to you mate.

I think you missed what Cuppa said about the ply. He was not suggesting it as a stone guard but rather fit the ply on top of the straps and the tank on top of the ply being the ply will spread the load and the straps won't eat into the tanks when full of water. I agree with Cuppa. Stone guard will help protect from punctures though for sure.

Great job mate! That chassis looks great. Do you know a good Welder.....

Augh yea i read that now.
The stone gaurds though completely cradle the tanks between tank and strap.
1 mill steel with 100mm fold up the front and 50 at the rear.
Ill keep an eye on it and if the metal starts to deforme ill throw some ply in it aswell..

[Clunk]

Derr Fred! Thought you especially would get subtle humour! :)
And so did I 😜

[Cuppa]

I think you missed what Cuppa said about the ply. He was not suggesting it as a stone guard but rather fit the ply on top of the straps and the tank on top of the ply being the ply will spread the load and the straps won't eat into the tanks when full of water. I agree with Cuppa. Stone guard will help protect from punctures though for sure.



Right, but not that the straps will eat into the tanks, rather that the additional support helps prevent the constant flexing of the bottom of the tank which eventually creates a weak spot.

[BigRAWesty]

So 200w pannel, mounts and a new ve blue charger solar controller on its way. Expected tomorrow.

[mudski]

Are you mounting the panel or will have it so you can move it around to chase the sun? I have 1 x 100W panel and 1 x 180W panel and we easily do 2 weeks parked up running two fridges/ freezer and lights on 2 x 105AH batteries. I use a little 10W panel too for the camper when its parked up to keep the batts charged. Works well.
I just need to find time to sell my camper so I can buy a Dove too. Very inspirational mate.

[BigRAWesty]

Are you mounting the panel or will have it so you can move it around to chase the sun? I have 1 x 100W panel and 1 x 180W panel and we easily do 2 weeks parked up running two fridges/ freezer and lights on 2 x 105AH batteries. I use a little 10W panel too for the camper when its parked up to keep the batts charged. Works well.
I just need to find time to sell my camper so I can buy a Dove too. Very inspirational mate.
Ow this one is a fixer mate..
Its bloody huge.. Going on the van..
Yea i realise 200w is way overkill but it gives me a great capacity even on overcast days..
I have a 120w folding pannel which we'll use to top up the car battery.
If shoit gets diyer ill be able to plug van gear into the car to aid the portable pannel..http://www.nissanpatrol.com.au/forums/images/imported/2017/05/18.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/05/19.jpg

[mudski]

200w is no overkill I reckon. Best to have too much than not enough. Our last two week trip my batts never dropped below 92% capacity the entire time.

[BigRAWesty]

200w is no overkill I reckon. Best to have too much than not enough. Our last two week trip my batts never dropped below 92% capacity the entire time.
Yea thats what im aiming for.
Much rather have to much than be worried about catching every possible ray..

[BigRAWesty]

Well after a 7000km 7 day extended trip aus post has finally delivered the rest of my gear..
Got the new controller in.
Boy it feels so much more solid than the old one..
Pannel on maybe tomorrow night..http://www.nissanpatrol.com.au/forums/images/imported/2017/05/65.jpg

[BigRAWesty]

Here we are.
120L in 2 tanks with full width stone sheilds on both..
Straps are offset to one side as the tanks are not full width and are actually centered to the straps..http://www.nissanpatrol.com.au/forums/images/imported/2017/05/82.jpg

[BigRAWesty]

Ow and the big 200w pannel on the roof.
Pic is just sitting there but is now down with sikaflex 291 marine grade adhesive..http://www.nissanpatrol.com.au/forums/images/imported/2017/05/83.jpg

[BigRAWesty]

Wiring complete..http://www.nissanpatrol.com.au/forums/images/imported/2017/05/226.jpg

[threedogs]

Augh yea i read that now.
The stone gaurds though completely cradle the tanks between tank and strap.
1 mill steel with 100mm fold up the front and 50 at the rear.
Ill keep an eye on it and if the metal starts to deforme ill throw some ply in it aswell..

It spreads the load evenly and holds the tank more securely you can buy them from
"huntsmans Trailers" but with your contacts etc you could get a Gal one knocked up in no time.
I'll be fitting my water tank with the full tank protection before I disappear off the planet for a while.
Start leaking water in the hot out back could turn nasty, you know the rules stainless fittings and Nylock
nuts washers etc. some insertion rubber to stop steel on steel is always a good idea, wheres the number plate light???

[BigRAWesty]

It spreads the load evenly and holds the tank more securely you can buy them from
"huntsmans Trailers" but with your contacts etc you could get a Gal one knocked up in no time.
I'll be fitting my water tank with the full tank protection before I dissappear off the planet for a while.
Start leaking water in the hot out back could turn nasty, you know the rules stainless fittings and Nylock
nuts washers etc.
All done mate a few posts up.

[threedogs]

All done mate a few posts up.

Coo,,,l looks awesome,,, mind not on the game ATM. Im hoping to get one as well in the coming months
So expect some PMs lol

[BigRAWesty]

Well..
Ok insurance come threw..
Wicked..
New canvas is on.
Tail lights finished.
Bed end frames repaired and straightened..
New ATM of 1400 and new vin plates on.
Kitchen is finished with chalk board paint on fridge front.
I think van is just about ready for the trip lolhttp://www.nissanpatrol.com.au/forums/images/imported/2017/06/72.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/06/73.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/06/74.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/06/75.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/06/76.jpghttp://www.nissanpatrol.com.au/forums/images/imported/2017/06/77.jpg

[mudski]

A big wow for you mate! I am very impressed with what you have done so far. This is exactly what I want to do, once I sell get of my rss and sell my camper. My missus loves your work too. That kitchen is real good. 10/10 so far bud. I'd love to see this in the flesh one day...

[MudRunnerTD]

Well..
Ok insurance come threw..
Wicked..
New canvas is on.
Tail lights finished.
Bed end frames repaired and straightened..
New ATM of 1400 and new vin plates on.
Kitchen is finished with chalk board paint on fridge front.
I think van is just about ready for the trip lol
http://www.nissanpatrol.com.au/forums/images/imported/2017/06/72.jpg
http://www.nissanpatrol.com.au/forums/images/imported/2017/06/73.jpg



Whats the story with the Insurance mate?

[BigRAWesty]

Whats the story with the Insurance mate?
Typical insurance, its never easy ey.
So they were happy to take on the repair.
But once i took it to the canvas workers they did the sums of repair and due to location of the tear, and how they did tents back in day, and they added some insurance (incase they tore it or whatever) it come out a couple hundred short of full replacment.
So seeing its insured for 5000 and canvas come out at 3000 it needed to be assesed, possible write off.......
So assessor come out and took photos etc and did his report.
Be he also reported that the van was in an un roadworth condition wuth mods been done, which i fully knew due to spring and axle upgrade.
But insurance started questioning draw bar, tool box, rear bar etc and it needed inspection..
So a quick call to transport sa and explained my mods and they saud uts all withing legal requirements, no inspection needed, just a new weight notice and vin plate with new atm and wheel size and alls sweet.
So i did have van booked in for new vin and compliance but wasnt going to worry with it if it got written off..
So got it all done and registered, emailed insurance and now all good.
Just a few curve balls along the way..