My Flip-Pac resto

[FlatBlak]

Hello all, new to forum today!:sombrero:

I picked up an old flip-pac from an Exp Portal member Bill, the one posted for sale in Corpus Christi TX. I got it back to my shop and cleaned it up a little bit as it had sat outside for 3 years or so.

It has the double rear doors and needs a lot of work but nothing I can't handle. Speaking of handle, I have to buy one along with some other parts from Flip-pac. I sent them an email...do they answer emails or respond best to phone calls?

Anyways this will be going on a 99 Frontier. I already have AAL and may add air bags later on. The short Summit AAL's give a lot of rear stiffness and it should ride pretty good with just the top. Eventually I'm sure I will have to add bags though as my "Farkles" (accessories) are accumulated.

The pass side hinge is in need of replacement as seen in the pics. Can someone elaborate on the best way to tackle this issue? I can't even figure out if the top should be open or if I can get to it from the bottom with the top closed. Also the torsion bar, will it need any preload to help lift the top from the closed position? A repair manual would be nice but I don't think they exist. Any help would be appreciated.

Everyone likes pics! :wings:

http://i869.photobucket.com/albums/ab254/heybensmith/CopyofIMG00162.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/CopyofIMG00164.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/CopyofIMG00165.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00166.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00173.jpg

[haven]

Welcome to ExPo, Flatblak! Let me guess the color you'll paint the repaired camper! Nice truck, BTW.

Speaking of repairs, can you speculate about the causes of the damage to
the fiberglass top? Is there internal damage, too?

[MotoDave]

red87 is working on a similar project, he might have had the same issues with the main hinge:
http://www.expeditionportal.com/forum/showthread.php?t=34459

[bucketosudz]

Welcome!!! X2 on the truck, got any other photo's?

[DaveInDenver]

That's some serious rot. :-/ It'll be worth it in the end, though!

[BlackX]

I'll enjoy watching this restoration. Great looking Fronty BTW :Wow1:

[FlatBlak]

Thanks for the warm welcome!:victory:

The P.O. redid the top with some type of marine core foam/plastic and did an excellent job on it. It's super stiff and in excellent shape.

I believe the hinge or the sleeve it attaches to on the pass side rusted and eventually broke through. In the 2nd picture from the top you can see the front where it broke the fiberglass, the 4th pic down you can barely see the break. It is broken completely through and will need completely redone. I have extensive fiberglass experience so this will be a fairly easy fix. Probably just a couple hundred to do it right and 300% stronger than original. I plan to redo the original design a little bit and gain some strength from the rest of the shell vs. just the front 6-8 inches.

I was able to get the top open....by myself. It wasn't pretty but worked like a charm. Picture 2 tie downs, a 100 ft rope, a 10 ft ladder and an old pallet. lol I already started tearing into it and it's not as bad as I had expected once I got it all cleaned up and evicted the previous rodent tenant that used it as his winter condo.

The tent really needs replaced but I'm not sure I can swing the cost yet. Anyone know where to get a parts list and prices? Does FRP have this available?

The truck is basically stock believe it or not. 3" body, torsion crank, AAL, Calmini steering, 35" Xterrains, 01+ fiberglass front end, Calmini winch bumper, 01+ CC rear flares modified for full size bed and a Navarra TD hood. I'll get some more pics as soon as I can but here are a couple old ones.

http://i100.photobucket.com/albums/m19/bonez34/101_0028.jpg

http://i100.photobucket.com/albums/m19/bonez34/101_0025.jpg

http://i100.photobucket.com/albums/m19/bonez34/101_0022.jpg

When I bought it....lol

http://i100.photobucket.com/albums/m19/bonez34/bens-pics-002.jpg

[TACODOC]

Welcome to ExPo!

Great project, truck looks good too for a Nissan :elkgrin: J/K

[mcm4090]

I have seen that truck on NOR. Impressive.

[FlatBlak]

Thanks! Not all of us have Toyota money...lol. I prefer toy's but Nissans have been very good to me. Their front end is weak but other than that they are very tough trucks. The Calmini steering bushings are shot, like everyone elses, but I plan to replace with bearings soon. Once that is sorted and new tie rod ends, BJ's I'll be ready for another 150k mi.:smiley_drive:

I have been lurking for quite some time, love your build TacoDoc as well as Red87's. His build is what sparked my purchase....along with lacking 4k for a new top.

[FlatBlak]

I have seen that truck on NOR. Impressive.

I remember you on there. It's been a few years, your truck is coming along very nicely! I saw Houdini's a little while ago...:Wow1:

I sold the Frontier to my friend and built a VH45 powered 300ZX. Then moved to FL and then to TX. Need a/c and the TX roads were killing the Z so we traded. Feels good to have a truck again!

[FlatBlak]

I was able to get quite a bit done over the past coulple days. It's still very structually sound with the exception of the steel tubes that run the length of the cap. These could be replaced with enough time and effort but I do not have as much time as I would like.

I was given a replacement hinge by the P.O. for the lower passenger side and had to take out quite a bit to get it in. The original tubing was in the way so I had to take a chunk of glass out to gain access.


Once it was in place I lubed the bolts up with anti-seize and tightened enough to hold the sleeve and existing fiberglass in place. You can barely make out the peice of the old tubing that I was able to leave in place to attach to the inside of the new tubing. It will give me a little more strength. The gap between the new tubing and the exterior panel was filled with resin after the outer layer was put in place. After this hardened I couldn't move the new sleeve no matter how hard I tried so I hope it's in it's proper place.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00188.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00189.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00196.jpg




The front was sagging so I used my imported custom made incrementally adjustable support structure to hold it up in place.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00193.jpg

I spend about 2 hours trying to find a local fiberglass supplier in Houston and finally gave up. There is West Marine but at 38 bucks a quart I settled on a gallon of Bondo resin from Auto Zone. I hate this resin but then again it's a friggin camper shell, my life really won't be in danger if it fails. Plus I can lay a ton of resin on it because a gallon is less than 40 bucks. I used mat but anything can be used. The rear flares on the truck have some t-shirts in them. lol Fleece works very well too because it holds a lot of resin and is super strong when set. I like to use the proper materials but I'll make do with what I have.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00197.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00199.jpg

The drivers side had broken through where the tent poles attach so the first layer was layed. I will definately need a few more though.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00190.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00200.jpg

[billith]

Hey Ben, nice to see the old Flip Pac again. When I had this, in the beggining I had to replace the other hinge. The channel of steel that houses the hinge rusted out, and the pressure from the torsion bar caused it to twist and rip through the rusted metal and fiberglass. I replaced the channel and fiberglassed it in and through bolted the hinge in through the fiberglass in through the steel on the drivers side with stainless steel bolts. I finished the repair, painted the Flip Pac, and used it for about 6 months when the otherside did the same thing with the hinge, but never got around to fixing it. The hand crank I had, had the splines wear out, so I tried to get a welder to just weld the hand crank on the torsion bar, but it wouldn't hold. That is why there is weld splatter on the end. I'm pretty sure with a little finess you can grind of the splatter so a new hand crank will fit. The torsion bar is still good to use. Yes , Flip Pac does sell the tents separately. I wrote to them last year and you can buy any part they have. I have been a fiberglass tech for 23 yrs. So if you have anymore questions feel free to ask Bill. P.S. you might have to keep on the Flip Pac people, because it took me 2 times emailing them and weeks in between untill they answered me.

[FlatBlak]

I was wondering what that was on the splines! I thought it was an old rusty cotter pin until I couldn't break it loose. lol

Not much progress due to rain so I started on the doors. Old rotten wood and styrofoam is being replaced by foam core and fiberglass skin. Turning out ok, it'll look fine with carpet on it but it turned wavy from lack of heat to cure it. Oh well, I just have to keep reminding myself that it's a camper shell and not a masterpiece. I do like to do things right but time is a mf.

On a side note the winds in S Texas were horrendous the past couple days. Yup, the whole flip pac fell off the sawhorses it was sitting on. I couldn't find any damage to it so that's good. Appears it's stronger than I thought when I initially unloaded from the truck by myself by dragging it on the sawhorses. I got about 90% unloaded and gravity did the rest. This is not a one man job, but I'm used to working alone so...:smiley_drive:

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00206.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00204.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00207.jpg

[FlatBlak]

The past few days I have been finalizing the doors, erasing old rivet holes and smoothing them down. They should be done in a few more days.

I was able to get a couple more layers on the inside layed down and it's nice and strong now. Put the carpet back up and am working on the mounts.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00213.jpg (http://s869.photobucket.com/albums/ab254/heybensmith/?action=view&current=IMG00213.jpg)

I also erased what appears to be an old spare tire access cutout in the lower door section. Here it is in it's new location. I was hoping I could keep the tailgate for a porch when I wanted to but it doesn't look like I can without major modification to this peice. I may look into it after everythings mounted but maybe I'll just ditch it.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00212.jpg (http://s869.photobucket.com/albums/ab254/heybensmith/?action=view&current=IMG00212.jpg)

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00211.jpg (http://s869.photobucket.com/albums/ab254/heybensmith/?action=view&current=IMG00211.jpg)


I also found a great use for my old bedliner. Strong and lightweight sand ladders! hehehe

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00210.jpg (http://s869.photobucket.com/albums/ab254/heybensmith/?action=view&current=IMG00210.jpg)

[FlatBlak]

I'm still working on everything but man....this is a lot of work! I had all of these ideas of customizing... but the farther I get the less I want to do.

This morning during my daily browse and sip session I was looking at the Earthroamer Jeep and the flush mounted lights in the top... great...another idea.

I don't hate many things, but I do hate bodywork. At least I don't suck at it.

[FlatBlak]

Today I was able to get the torsion bar re-installed in the brackets. I should have done this earlier. Anyways I again used my rope, ladder, pallet and added in a winch for the pull up. Overkill but it worked. After laying the top onto the cap it was definately cockeyed. This was due to the mounting of the pass hinge I did. I unbolted it and set it into the proper place and everything lines up now. I will have to drill new holes in the glass and sleeve to accomodate it's new position though.

Post vertical...

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00264.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00265.jpg

Looks good from 50 feet!:sombrero:

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00267.jpg

Finally back together and square. It's amazing how much weight the torsion rod nulls from the top. I am wondering if the torsion rod is from a mid-eighties car or truck...I swear I've seen one very similar before.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00268.jpg

[FlatBlak]

I found out a couple days ago I am moving back to Miami on the 15th so the project hit warp speed. Long days and nights but it's all coming together.

The rear doors and lower section attached to make sure everything lines up. I am a big fan of the rear doors but at the same time I'm sad because I have to lose my tailgate. I am planning to make a swing away tire carrier on my vacation in July so it won't be a total loss.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00282.jpg

I taped off the trim around the top and ran a bead of 5200 around it.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00281.jpg

Here I had to cut off the front so it would fit on my bed. The front was about 4 inches too long for the Frontier bed style. Underneath was wood so I just layed on some short strand filler to keep water out, then sealed with primer before paint.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00277.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00279.jpg

This orbital sander I picked up at Harbor Freight for 20 bucks has survived probably 20 hours of use in the last few weeks and works great!

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00294.jpg


I have yet to hear back from Flip Pac regarding parts so I made a trip to West Marine and picked up some bimini top poles and ends for the support struts. Expensive at $60 but they had everything I needed, and at 7pm on a Saturday night I can't complain.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00288.jpg

Ready for paint...

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00290.jpg

So I started spraying using my little 2 gallon brad nailer type compressor. Big mistake. In about an hour I had one door lightly painted and started on the next before I had enough. I hadn't planned on buying a compressor until further down the road but I needed one so I went shopping. I had planned on buying the Puma 12v for OBA, however this was obviously not going to happen now. HF was closed for easter so I went to Home Depot, which gave their 5 minute closing announcement as I walked in the door. The Puma runs about $200 so I wanted to keep in that price range.

I had already planned to buy a 2kw invertor down the road so I had roughly 15 amps to play with. The old lady needs her margarita blender and hair dryer right?

I ended up spending $250 on this one. It pulls around 14 amps which is quite a heavy load, but it puts out 4.9cfm at 90psi! This thing actually cuts off while spraying even with a small 4.5 gallon tank. Eventually this will be my OBA, mainly because I don't have my own garage to keep it in. It is very heavy around 60lbs so I am going to look into ditching the steel tanks for an aluminum 5-7 gal.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00297.jpg


Everything looks better in FlatBlak!

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00292.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00293.jpg

[billith]

Ben, your doing a fantastic job on the Fip Pac. You seem to know what your doing. I really like the pictures and all the work you have done. It will all be worth it in the end, and then you will have a very cool old Flip Pac to enjoy. Even though I sold it to you and posted that on this site, people are still calling me about it asking if I still had it for sale. Keep up the great work dude.

[partsflyin]

This is coming along great!! i love it!

[FlatBlak]

Thanks fellas, maybe someone else will be inspired by my thread... like I was when I found this site!

Today I was able to get it mounted, it looks a bit out of place, but I think only because I have never seen this truck any other way. I think it will grow on me and not look so big after I get my hi-lift, tire carrier and foxwing awning mounted. All homebuilt of course.

Sorry for the quality of all of the pics, the Blackberry is all I have.

Bring on the forklift...

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00299.jpg

8ft ladder for height reference

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00303.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00307.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00308.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00306.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00309.jpg

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00311.jpg

[akfj40]

that looks awesome! good job:victory:

[partsflyin]

Saweettt!!!!

[billith]

Ben, it looks great. You don't mess around.You got a lot done very quickly. I think it looks good on your truck.

[suntinez]

I think you've done a great job on this, congrats!

It looks really good on your truck, does take some getting used to. I've never seen one with a blue canvas tent, looks to be in pretty decent shape too.

[SLO_F-250]

SICK SETUP! You are making me re-think my build now!! :Wow1: Congrats!

[FlatBlak]

Thanks all! Most of my ideas come from you yourselves so I don't take much credit, big thanks to you all for sharing your builds!!!!:victory:

I expected to have more time to work with it before my trip back to Florida but that was cut short. It was cut even shorter today when they asked if I could get on the road Saturday. lol They like to do that to us so I started finishing up and packing some stuff today.

Not much progress on the top today worth showing except one cool thing, my old toolbox fits inside and opens fully as well. Sweet!

The canvas is in fair shape, a lot of small little holes and the big tear on the passenger side by the hinge. I plan to patch up the holes, buy the rain fly and just roll with that for a while. If I get enough use out of it, and can justify a new tent, then I'll buy one. I will still make out cheaper than a new FP in the end, a lot cheaper.

I ended up with around 11.5 inches of space under the toolbox, more if I raise it up. Perfect place for my OBA and OBW down the road.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00316.jpg

[FlatBlak]

The last update for a while. Probably weeks until I get settled again. I was able to get the Hi-Lift mounted. The instructions said to mount the brackets horizontally but I mounted them vertically for as much vertical strength as possible, and it worked too because I can do pull-ups from the jack. lol

The truck definately rides better with the extra weight, as far as ride quality goes, but with all my tools and stuff it's pretty scary when it starts swaying. Looks like airbags are more needed than I thought.

http://i869.photobucket.com/albums/ab254/heybensmith/IMG00318.jpg

[Thunderbear]

So when are you going to get some RIT dye and dye the tent flat black? :sombrero:

Killer work. Can't wait to see what you do inside as it evolves. 'Murdered out' is not a look you see on expo trucks that often :bike_rider:

[FlatBlak]

Lol, I would actually like a nice new tent in the, what is it....light gray color? One CAN have too much black I suppose.

I had big ideas of building the inside like a boat, textured fiberglassglass floor, nice shiny white fiberglass cabinets, shower, etc. I'm getting tired of itching and after those simple repairs it re-occurs to me how much work it is.

I need to use it first so let's see how the old lady likes it and we'll go from there. She grew up on a farm in Honduras, not scared of much, not afraid to get dirty... yet I have never seen her dirty. She struts around in her Beemer with $500 sunglasses and a purse that reminds me of my grandma's wicker rocking chair... but costs more than my FP did. I'm going to take her shopping at wally world and show her the Appalacian Mts. with the FP, if it's a success we'll know soon enough. If not then I won't lose much when I sell it...or sell out I guess I should say.

'Murdered out' gets me more looks and comments than I care to have. If I could do it over I would have left the truck as is when I got it.

<---Big Dummy.

[Thunderbear]

Lol, I would actually like a nice new tent in the, what is it....light gray color? One CAN have too much black I suppose.

I had big ideas of building the inside like a boat, textured fiberglassglass floor, nice shiny white fiberglass cabinets, shower, etc. I'm getting tired of itching and after those simple repairs it re-occurs to me how much work it is.

'Murdered out' gets me more looks and comments than I care to have. If I could do it over I would have left the truck as is when I got it.

<---Big Dummy.

I like the idea of the fiberglass, but it is exceptionally un-fun to work with. Cutting granite countertops with a glas backing left me without fingerprints for months. Still, that would be unique I think here on ExPo, I can't think of anyone who's glassed the inside of a camper from scratch.

I like the flat part, but my expo vehicle is going to be flat textured tan or OD.

What color was it?

[blackout99]

Hey Flatblak, just wondering if you have made any progress on the camper since your move. I also have a 99 Frontier, and i have started looking for a Flippak myself. :coffeedrink:

[Scoutman]

Just read this and I must say amazing work. I think the FP on the rear looks awesome and after you get a spare tire rack and finish out the inside, it will really be a nice rig to roam in.

You mentioned running that compressor off of a 2kw inverter, you may need to go back and double check your numbers but I don't think it will work. I tried a similar plan running a 1hp 3gal craftsman small compressor off a Cobra 1500w inverter and it just wouldn't cut it. The initial surge was too much. Wouldn't want you to make the same mistake.

Very cool that the toolbox fit inside the FP. That's something I'm missing with my pop up truck camper is having to take my box out and tailgate off. That should make a great double duty bench seat and storage box inside. Also, 11.5" under that toolbox is about a perfect size for milk crate storage. :sombrero:

[FlatBlak]

I have not made any progress since moving. I'm actually thinking about selling it, no time money or dirt. I travel the world for a living and just got back from a 7 week trip in Alaska. The last thing I want to do right now is take a vacation into the wilderness. lol

If anyone is interested shoot me an email. I am located in Miami FL, 500 bucks takes it with the Hi-Lift.

heybensmith at gmail dot com

[FlatBlak]

Shifting gears again. This truck will be on ebay soon. I traded my 300ZX to drive this truck and am looking to buy a new Z. My friend who owns the truck wants to sell it to buy my old Z so we are going to put it on ebay tonight. I will be driving the truck back to VA for my vacation on the 2nd and after the auction is over the truck will be available for pickup in Va Beach VA. Anyone interested before auction ends let me know. I will be travelling up I-95 from Miami so cash offers could get free delivery. I don't know what it's worth, money talks. We are going to leave the flip-pac on it as well as everything else, stereo, recovery accessories, etc. Lots of extras! :wings:

heybensmith at gmail dot com

thanks,
Ben

[FlatBlak]

:smiley_drive:
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=270599638308&ssPageName=STRK:MESELX:IT

[FlatBlak]

Auction just updated with new info, pics and more goodies!!! :wings:

[thebrassnuckles]

i saw that the auction ended.. if the price shown no there is correct, I am so mad I didnt find this sooner..