FG in a box!!!

[whatcharterboat]

Hope you find this interesting. I know there were alot of questions raised about containerization once before so......

Went down to Brisbane to help with the loading of the RTW truck bound for South Africa. We were only there just in case of any technical problems. The loading was done by the professionals. Only thing was they weren't quite ready for the truck. Little communication problem between the guys responsible for the loading. Anyway we made a start to see if it was all going to fit even though they didn't have the tie-downs organised.

Firstly the overall length of the truck was only a couple of inches too long so it was always going to have to go in a "high cube" 40ft container instead of a standard "high cube" 20. Apparently 30's are pretty hard to come by but that would have done. Taking the spare wheels and the 2 extra tyre carcasses off and possibly stowing them inside might have seen it in a 20 if it was that important.

Originally we thought that the 4 x 19.5" wheels would have to be swapped for standard wheels with some old 7.50R/16 tyres to lower the height as the long travel suspension sees it sitting up quite a bit higher than normal. So we got 4 together beforehand in case.

http://farm3.static.flickr.com/2678/4334697260_57d9cf7f2c.jpg

Body clearance was OK but the mirrors only just made it. Reversing it in straight was much harder than we thought. It just would not go in straight. Very hard to drive it in looking through the mirrors when the truck just disappears into the darkness. No problem for the professionals though. They simply nudged the back of the container around with a forklift.

http://farm3.static.flickr.com/2735/4333961443_fe47e8bf75.jpg

In the end we had to swap the front wheels only. It was either that or remove the roof rack. Only 4 bolts holding it on to the scrub bars but the comms guys hard wired and glued the sat antenna to it so it was easier to just swap the wheels and with a spare 20 feet in the box there was certainly an abundance of room to stow the others.

http://farm5.static.flickr.com/4011/4333968123_2c6eed5933.jpg

Note the pad made from wooden pallets. Again, made things easier to load as the truck went in very level. If you were wondering, the truck was pushed in the rest of the way. Actually it was pushed all the way into the centre of the container to balance the load and the guys slid under the diffs to tie/dog it down. When I slid under the diffs in a T-shirt I got plastered by splinters off the floor. Ouch. Worst thing was how hot it was on the day. I needed to lose some weight anyway.

Apparently the wheels were well tied down as was the body to eliminate any swaying movement. Not sure if they ended up using chains and dogs or heavy tiedown straps but I'm sure Robert will eventually have something in the diary on his website about this www.doubledutchworldsafari.com. A double ended container would have been handy for this but they can be hard to get too, and as we said, you can get by anyway. Just watch out for splinters.

Oh BTW the batteries were all disconnected before it was pushed the last bit of the way.

[ThomD]

Wow.

So how do they secure the back end and then get out? Crawl under the truck?

[whatcharterboat]

Hey Thom, How are ya?


the guys slid under the diffs to tie/dog it down.

Yep. Not really a problem with an FG even with the standard wheels and tyres (and a standard waistline. Lol)


When I slid under the diffs in a T-shirt I got plastered by splinters off the floor. Ouch. Worst thing was how hot it was on the day. I needed to lose some weight anyway.

Regards John

[Token]

Man that's a tight fit.. I'm betting by the time it gets to Africa there's some sort damage on the top edges of the rear box from rocking around..

Hope yall included unpacking instructions in the box..

[kerry]

Excellent pictures and description. When you say it was pushed in, do you mean by hand or with something like a forklift? It seems that the driver would not be able to get out were it driven in? I like the pallet idea. I had nosed mine up against a container we have a school and wondered how much of a problem the angle would be with one set of wheels inside and one outside. Was there a specific reason for disconnecting the batteries or just a general precaution? Was there any issue about whether there was propane in the tanks or not?

[dustboy]

Wow, cool. I was going to ask how ya get out of the cab once it's in, but I guess that's what the forklifts are for!


Man that's a tight fit.. I'm betting by the time it gets to Africa there's some sort damage on the top edges of the rear box from rocking around..

They filled it with styrofoam peanuts.:sombrero:

[kerry]

I remember seeming pictures of a VW motorhome shipped across the Atlantic in a container. They draped the vehicle with moving blankets to protect it inside the container. Don't know if it did any good but they don't take up much space and I doubt they are very expensive.

[whatcharterboat]

Man that's a tight fit.. I'm betting by the time it gets to Africa there's some sort damage on the top edges of the rear box from rocking around..

About 4" on each side of the body at floor level. The walls slopes in so there's about 7 " on each side at the top. As I said, I didn't see the final tie down but the plan we discussed was to tie the truck in by the wheels (or possibly the diffs) and also to tie the body at the recovery points on the front and rear bars to limit any movement through the suspension. I think everyone was very confident of a safe trip.

http://farm3.static.flickr.com/2747/4336341340_4abb9a3eff.jpg


Wow, cool. I was going to ask how ya get out of the cab once it's in, but I guess that's what the forklifts are for!

Nah, the owner drove it in as far as he could. After that , it was an easy thing for a couple of guys to push. Remember it was all level cause of the pallets.

As for the batterries, ....disconnected to eliminate as much discharge as possible and also for safety sake I suppose. LPG (our version of propane) was in 4 x bottles not tanks which are held in cradles under the body. The fuel and water tanks were all full to help weight it down ...that was the plan anyway. Let's see how it all went in 7 weeks when it gets opened up in Durban.

[daniel ruops]

John;

You were not wearing the hat that I so kindly sent you for your birthday....

[whatcharterboat]

Dan. Very sorry . Guilty as charged. You got me. Obviously something that gives more shade than the average Aussie verandah would not fit under the FG diff so I opted for my new and more compact Fuso cap. Hope no one from Isuzu ever reads this though. Haha.

http://farm3.static.flickr.com/2572/4336520839_b349449e0f.jpg

[DontPanic42]

This is completely off topic but the title "FG in a Box" got me to thinking. Always a dangerous thing. Does anyone make a diecast model of a FUSO? I expect I am not alone in collecting diecasts of the cars I have owned over the years - 2 "67 Camaros (the original in "67 and the one I have now), '69 Charger, '70's El Camino, "54 Bel Air, etc. Toyota even sent me an FJ like the one I bought in '06. It would be great to have a FUSO and try to make it look like the "RoadHippo"

[ThomD]

Hey Thom, How are ya?



Yep. Not really a problem with an FG even with the standard wheels and tyres (and a standard waistline. Lol)



Regards John

Hi John,

Soggy here. Winter is the rainy season and we've been making up for a 3 year drought. Other than that, mostly working.

Keep posting, because it inspires us dreamers.

[Tony LEE]

Any figures on the total transport costs?

Be a couple of years before I might need to take my OKA overseas, but it would be nice to get a ballpark figure.

[whatcharterboat]

Hi Tony, Sorry. I never asked. Send him a message through his guestbook on his website. www.doubledutchworldsafari.com

[Harald Hansen]

I spoke the other day with a bloke who had sent his Defender 110 from Norway to Australia and back in a container a few years ago. The costs came to about $5000 in US money. Just a ballpark figure for you, and it might be cheaper these days because of the economic climate.

[VicHanson]

Has anyone every swapped vehicles with someone else on a different continent for a few months or more, instead of shipping? Seems like it would be a good option instead of spending $5000 or so shipping. I am hoping to go to Europe in a few years, but definitely won't be shipping my camper due to costs.
Vic

[Harald Hansen]

The people I mentioned considered outright buying a vehicle in Australia, and selling it at the end of their trip. They decided against this, as other people's experiences added up to a loss of on average approximately the same amount as shipping their own vehicle would cost. Less hassle when they didn't have to deal with buying and selling as well.

[whatcharterboat]

The people I mentioned considered outright buying a vehicle in Australia, and selling it at the end of their trip. They decided against this, as other people's experiences added up to a loss of on average approximately the same amount as shipping their own vehicle would cost. Less hassle when they didn't have to deal with buying and selling as well.

Hey, Harold. My brother just sold his 110 Defender (really well set up too) for the approximate equivalent of $5000 USD (supposed shipping cost).

[gait]

thanks for the pics John. Good to know it fits with the large wheels - phew!

[kerry]

Has anyone every swapped vehicles with someone else on a different continent for a few months or more, instead of shipping? Seems like it would be a good option instead of spending $5000 or so shipping. I am hoping to go to Europe in a few years, but definitely won't be shipping my camper due to costs.
Vic

I've swapped with a couple from England. (at least they used ours, we haven't used theirs yet).
In 2001 I bought a Mercedes 307d motorhome in the UK. Used it on three separate trips to Europe, keeping it a farmer's barn when I wasn't using it, and sold it at the end of the summer of 2003. Paid $1700, sold it for $2100.
I had planned a swap in Australia last summer but the daughter of the guy I was going to swap with decided to get married so couldn't swap.

[dzzz]

I'm curious what the realistic largest vehicle size would be? I believe the door is 8ft 5ins by 7ft 5 ins wide on a high cube.

8' 3" x 7' 3" ??

my unimog is 9'10" on 47" tires with 20" rims.

[Ford Prefect]

So take the tire off the wheel, and just pull it in on bare rims???

Thanks for the thread, this has been interesting to look into. WOW they are going to do a lot of driving in the next five years... Wish them the best of luck!

[Ford Prefect]

By the by....


Do you have any photos of the truck with the roof raised? Any one how they did that? Any on the interior? Would love to see a bit more about the vehicle it self, but their page says very little. Any sort of build thread that you can point me towards?

Cheers
Brian

[Lynn]

Went down to Brisbane to help with the loading of the RTW truck bound for South Africa. //snip// Originally we thought that the 4 x 19.5" wheels would have to be swapped for standard wheels with some old 7.50R/16 tyres to lower the height as the long travel suspension sees it sitting up quite a bit higher than normal. So we got 4 together beforehand in case. //snip// In the end we had to swap the front wheels only.

Hey John, what am I missing here? If I'm reading this correctly they shipped the truck off for their African adventure with a spare set of 'standard' rims/tires to haul around? I assume that they will need them whenever they ship again, right? Did you discount the use of simple disk wheels that you have talked about in other threads?

[Willman]

Cool thread...

Any tighter.....butter would have been plan "B"

Keep us posted when you open her back up!

:)

[whatcharterboat]

Do you have any photos of the truck with the roof raised?

Brian I have plenty of pics from the beginning. We built the base frame on the chassis but didn't have time to build the whole thing so the owner took the next best option and got us to do what we could and a local offroad caravan builder to build the living quarters on top of that. There was always going to be issues when you get different companies involved in one build. Obviously we would have preferred to do everything but it just wasn't going to happen in the timeframe with all our other job commitments.

Sorry rambling.

http://www.doubledutchworldsafari.com/ddws100/photos/p3/Bushcamp%20Elliot%20Falls%201%20(1).jpg



Any one how they did that?

Originally the lift was done by an RVAirlift (google them, very cool, cheap, easy) but because they couldn't fit a 4th scissor on the left side under the awning, the roof didn't like to lift evenly so we were later asked to come up with something as an alternative. We used 4 x IP65 rated electric actuators run through a synchronized control module. True synchronized operation. Unfortunately they had to go on the outside but could have been planned for earlier and concealed. AHH, maybe I'm being too critical. BTW I'm going to post a heap of pics on that MAN we built next week. It's got a hydraulic lift that is pretty neat.

http://www.doubledutchworldsafari.com/ddws100/photos/p3/Rear%20of%20Truck.jpg



Any on the interior?

Looking aft. Shower and toilet in the front righthand corner. Fridge at the front on your left as you enter. Only have a couple of the living quarters being built but don't feel right about posting build pics from someone else's factory. I'm sure there will be plenty more on the Doubledutchworldsafari website in time. BTW every time you load the homepage a different batch of pics loads.

http://www.doubledutchworldsafari.com/ddws100/photos/p3/Our%20Living%20Qtr%201.jpg



Would love to see a bit more about the vehicle it self, but their page says very little. Any sort of build thread that you can point me towards?

Hey, you can see the old RVAirlift a little better here. So anyway, I already posted a couple of when the bar work and suspension was getting done. I'll have a look for some others.

http://www.doubledutchworldsafari.com/ddws100/photos/p3/Truck%20set%20up%20for%20Bushcamp%20with%20BBQ.jpg

John

[whatcharterboat]

Hey John, what am I missing here? If I'm reading this correctly they shipped the truck off for their African adventure with a spare set of 'standard' rims/tires to haul around? I assume that they will need them whenever they ship again, right?

Hi Lynn, Well as I said, they only put the small wheels on the front and that was cause the comms guy hardwired the sat antenna to the roof rack which was originally intended to be quickly removed from the scrub bars for just that purpose. So even removing that would have dropped the height enough not to change the wheels. Actually he could have got by on the big wheels and tyres and just dropped the pressures but as he had the wheels on standby, he thought it would be safer to go that way.

BTW they won't be carting them around. That was never going to happen.



Did you discount the use of simple disk wheels that you have talked about in other threads?

Yer, Lynn. They were only going to work on an FG if you were loading into a double ended box. You still need to crawl under the diffs to get out remember. But you could save quite a bit of height by going to discs or a better way of looking at that would be you could have a higher body on the back. Maybe not high enough to get away with a permanent hard top though so why bother.

I do remember talking discs awhile back but after this experience I can't see the need. It was pretty easy when you got a couple of experienced shipping guys together.

http://www.doubledutchworldsafari.com/ddws100/photos/p3/Oops%20we%20forgot%20the%20tyres%20in%20the%20cont ainer%201%20(9).jpg

The tyres you see in the front of the truck are the 2 from the front axle and 2 spare casings that they are going to carry on the roof rack. As well as the tie down straps you can see, the truck was chained or tied securely around the wheels. The ones you see were to limit body roll.

[Lynn]

Thanks, again, for continuing my education. You have been a font of knowledge, and I really enjoy looking at the trucks you guys build.


BTW they won't be carting them around. That was never going to happen.


I assumed that they would have to carry them for whenever they ship the vehicle again, but I guess they should have plenty of time to redo the GPS antenna mount.

[whatcharterboat]

I assumed that they would have to carry them for whenever they ship the vehicle again, but I guess they should have plenty of time to redo the GPS antenna mount.


Yeah, They could have easily made it removable and it won't be that hard to do in a workshop in Africa. We just weren't going to tackle it outside the container door for fear of damaging anything.

The owner certainly wasn't worried at all. He said if he really had too he would just pick up 2 more wheels in Vladivostok or where ever. OR let air out. He was a little concerned about dropping air out too much and damaging the tyres over the long trip while tied down.

[Ford Prefect]

Wow, what a build.

Personally I could not see myself setting out on a trip that big, but I guess after having done several trips of shorter durations they are ready for something this long. Amazing thought.

VERY looking forward to the MAN build thread, thanks for sharing.

Thanks also for the photos inside. Do you have any with the new lifting system holding open the roof?

Very interesting indeed. I wonder how well it will do in the cold weather...That canvas section between the cabin and roof seems like it would let a lot of heat out.

Brian

[4xdog]

Watching that truck get slotted into that container has been fun. I'm kinda glad it isn't my truck I'm watching though! The nerves would get to me.

My company has used, and I've seen used, various forms of air-filled dunnage bags to prevent loads from moving after containerization. Sort of a big, flat, industrial strength inflatable pillow that cushions and immobilizes the load.

John, have you ever considered using dunnage bags to protect a vehicle inside a container?

Don

[Tony LEE]

Has anyone every swapped vehicles with someone else on a different continent for a few months or more, instead of shipping? Seems like it would be a good option instead of spending $5000 or so shipping. I am hoping to go to Europe in a few years, but definitely won't be shipping my camper due to costs.
Vic

Too many potential hassles over a swap, especially if there is any damage.

We bought a 7m motorhome in Germany with the intention of returning each year for several years and after two lots of 4 1/2 months, it has proved so convenient that we have done the same in the US. Only problem with 4 vehicles in three countries is the lack of months in the year to give them all a run.

If it costs less than $10,000 to get the OKA to S America and back, and we use it over there for a year or two, then I would see that as preferable to buying something over there.

[whatcharterboat]

My company has used, and I've seen used, various forms of air-filled dunnage bags to prevent loads from moving after containerization. Sort of a big, flat, industrial strength inflatable pillow that cushions and immobilizes the load.

John, have you ever considered using dunnage bags to protect a vehicle inside a container?

Hey Don, Good to talk to you.

The answer is "No". Don't know anything about them. Got any pics? I'd certainly like to know. Not that I plan on making a career out of putting trucks in boxes but it sounds like it would definitely be a suitable safeguard that might interest a whole new generation of inter-continental truck travelers.

[4xdog]

Hi John --

Good to talk to you, too.

Here is a link to a photo of dunnage bags in use:
http://www.jamesluke.com.au/images/upload/DunnageBagPP.jpg

Here's a link to the Wikipedia article discussion on dunnage bags:
http://en.wikipedia.org/wiki/Dunnage

Here's an Australian supplier (the one the picture is from):
http://www.jamesluke.com.au/cargo_care_dunnageairbags.html

Regards,

Don

[gait]

don't know if you used them but JamesLuke also provide dessicant bags to reduce container condensation.

[whatcharterboat]

Meanwhile over at Durban.............Imagine first seeing this and praying it's not yours.

http://www.doubledutchworldsafari.com/ddws100/photos/p5/This%20container%20fell%20on%20the%20warf%20and%20 in%20the%20water%201.jpg

http://www.doubledutchworldsafari.com/ddws100/photos/p5/Custom%20breaking%20seal%20and%20inspecting%201(1) %20.jpg

http://www.doubledutchworldsafari.com/ddws100/photos/p5/Custom%20breaking%20seal%20and%20inspecting%201%20 (8).jpg

http://www.doubledutchworldsafari.com/ddws100/photos/p5/Unloading%20the%20Truck%20in%20Durban%20(7).jpg

Bet he's glad that's over. Kicking back at Nathalia Beach. BTW Does that fence look electrified???
http://www.doubledutchworldsafari.com/ddws100/photos/p5/Nathalia%20Beach%20Resort%201%20(1).jpg

[whatcharterboat]

If you're interested.................An article on the truck in the current Fuso Smart Moves magazine

http://www.doubledutchworldsafari.com/ddws100/display_article.php?article=2

[FusoFG]

The article says there were no changes to the Fuso driveline???

Other than the srw and the steering damper that can be seen from the pictures, any other changes?

[whatcharterboat]

The article says there were no changes to the Fuso driveline???


Hi Tom, How are you? Yeah, we got a kick out of that line too. Technically the driveline is standard. The engine copped a DP Powerchip and 3" mandril bent exhaust and a couple of minor instruments (boost gauge, low coolant level warning) but after trialling a NoSpin diff (Australian Fuso dealer fitted option) up on Cape York the original LSD was refitted. That was it.


Other than the srw and the steering damper that can be seen from the pictures, any other changes?

Yeah plenty. Did you read the "rides like a Benz?" comment too? Front had sway bar, five link coil suspension, Polyair levelling bags, RTC damper, Rear had Watts link coil suspension with Polyairs and there were our Roboshocks all round with incab adjustment. So other than that it was absolutely stock standard. lol.

http://farm5.static.flickr.com/4058/4428315590_20e1eaf081.jpg

[Bajaroad]

The engine copped a DP Powerchip and 3" mandril bent exhaust and a couple of minor instruments (boost gauge, low coolant level warning) but after trialling a NoSpin diff (Australian Fuso dealer fitted option) up on Cape York the original LSD was refitted. That was it.






John, do you put the DP chip on all your conversions? How does it perform? Does it really improve fuel economy? Any down sides?
. . . . and most importantly will it work on my California truck??

[whatcharterboat]

ohn, do you put the DP chip on all your conversions? How does it perform? Does it really improve fuel economy? Any down sides?
. . . . and most importantly will it work on my California truck??

Hey Brent, Can I get back to you in a day or so? Got sidetracked on the Isuzu thread and your question is probably worth a thread in itself so I'll write something up tomorrow night.

Cheers mate. Hope you're having a good weekend. John

[Bajaroad]

Hey Brent, Can I get back to you in a day or so? Got sidetracked on the Isuzu thread and your question is probably worth a thread in itself so I'll write something up tomorrow night.

Cheers mate. Hope you're having a good weekend. John

No worries - take your time. You may need break after that one :)

After reading the Isuzu thread, the obvious question (which may have been answered already) is why does ATW choose the Canter for most of their builds?

[whatcharterboat]

No worries - take your time. You may need break after that one

Brent, you are so lucky you don't have the 4.5 / 6 ton "FG VS anything" option in the US. My brain hurts. Got a spare room?


After reading the Isuzu thread, the obvious question (which may have been answered already) is why does ATW choose the Canter for most of their builds?

Actually , Brent I did a rough count and it's about 50:50 . Since I started we've done only 1 more NPS camper than FG and with the buses it would be very close ratio too. You see, we always leave the decision up to the owners as we aren't locked in to buying from one manufacturer. We don't buy a packet of trucks to get a bulk discount and then try and flog them regardless. Sure we offer advice either way, but it really depends on very specific end user needs.

As an example, you wouldn't have seen any of these before, I don't think. The last white one is for one of the remote Aboriginal communities. We've done a few for them now. This first pic is one of my favourite NPS's.

http://farm5.static.flickr.com/4044/4510343635_cb6b472925.jpg

http://farm3.static.flickr.com/2277/4510980354_4890b1ba5c.jpg

http://farm5.static.flickr.com/4001/4510977132_71afffea71.jpg

http://farm5.static.flickr.com/4020/4510327667_a51e5b7c82.jpg

BTW We are looking at some big mining jobs and now that we are getting airbags on all the FG's , most of those will likely be FG's to due to the price. The mine vehicles get abused like you would not believe and as a result they will change the cab chassis and swap the bodies over every 2 years probably. So that's quite a saving with that sort of turnover.

http://farm5.static.flickr.com/4051/4480868359_ceb7e4579d.jpg

Now about your chip question.


John, do you put the DP chip on all your conversions?
No. The decision is left up to the owner and they may have them retro fitted although some of the dealers will fit DP Chips as a sort of dealer option before it leaves the yard so they may already have them before we start a build.


How does it perform? Plenty more acceleration, especially if you have a good exhaust to go with it. "Do you need the power?" That's the question. I don't have an oponion either way. Everyone I ask who has one says "it was worth it...like an extra gear...better on the hills" etc. I'd do your exhaust before anything else IF (note the capital letters) you were looking for a power mod. 3"mandrill bent. The FG exhaust is virtually the same as it was in the beginning even though the engine capacity has greatly increased and they added a turbo. One of the Chip specialists here does an awesome exhaust and matching chip package for the FG's. TaipanXp. Google them. Very trick but more bucks.

Plenty of different chips here. DP is the most common and the one our Fuso dealer carries. "Steinbauer" is another. "Chiptorque" guy's are very helpful (and must drink too much caffiene). Many of them (on the FG84 anyway, ) just raise the pressure in the fuel rail to trick the computer. Some go as far as altering air flow as well but I'm no expert in this and you really need to talk to one to get it right. With the 649's the process is different but the end result is the same. More fuel so more accelleration /power.


Does it really improve fuel economy?

Debatable. Sure that's what they claim but more power comes from using more fuel and if you have it you'll probably use it faster. Again I'm not an expert. Also alot depends on how well it's dialed in. Most of the guys run dynos for that or there are some good 'ol boys who just drive them and know how to tweak by ear.


Any down sides?

Warranty. You need to make sure you cover yourself. Here if the delaers won't cover the engine under warranty some of the Power chip guys will take over the warranty. Talk to "Ozzyfishaman". John's a wealth of info regarding chips.


. . . . and most importantly will it work on my California truck??

I'd be trying to get a chip guy in Cal to start with. I'm sure there would be something there already that could be adapted.

Brent, really like the way your truck is starting to look. It's quite different, heh?

Ciao for now. John.