1999 Chevy S10 ZR2 Camper build.

javajoe79

Fabricator
I realized that I posted in the wrong section before so I am reposting this build here. Mods feel free to delete my other thread. Thanks



So I have finally started on this build. I got the bed and rear glass removed to start with. Then I ordered some baja style front fenders to help fit 35" tires as well. They should be in this week. Then I got to work on the frame. So far I have a basic floor frame and I have all the material on hand to build the rest. The box will stick out a good bit on the sides of my S10 but I didn't want to compromise fitting a queen bed sideways and in the future I may end up putting this camper on a larger truck. Not sure on height yet but I am thinking about 90" from bottom of camper to the roof. It will hinge at the front and have the door on the back and be totally hard sided. Construction of the body and frame will be almost entirely aluminum square tube and sheet. 2" x .120" tube for the main frame with 1" x .062" for triangulation and for the roof structure. I will skin the corners in .062" sheet so they are a bit sturdier and I will skin the rest with 18 or 20 ga. The floor will probably be .095"

Specs will be as follows. 84" wide and around 145" long. Queen bed entirely over the truck cab. There will be wheel wells built into the camper body that will fit 35" tires at stock ride height for my ZR2. I may end up with different wheels to widen the stance a bit in the future but for now the stock wheels will work. On that subject I am on the hunt for a narrow 35" AT or MT tire. Something at most 10.5" wide. Not many options out there so if anyone has any leads please speak up. Diesel engine swap. Probably a Cummins 6BT in stock from to keep it simple and reliable. To go along with the diesel engine I will have a diesel stove, heat and water heater and I will tie that all in to the main fuel tank as well as the engine coolant for preheating in cold weather and for hot water courtesy of the engine at times. I think rather then an on board generator I will use the engine and a large alternator or alternators to charge the house batteries and run electronics. I hope to eventually have AC and fridge as well.

My main goal at this point is to build a weatherproof box with a bed and a door. This will also have a pass through built into the truck cab.

Looking for recommendations on the following:

Tall and narrow 35" tires.

A good sealer for the body panels.



So yeah.... here are a few pics...

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DanR7985

Observer
Looking forward to the future of this build. I had a 99 GMC Highrider, and I loved that thing. I was young and tore the crap out of it though. Blew one engine and almost another before I got rid of it. I still wish I had it sometimes.
 

javajoe79

Fabricator
Did some quick searching and Interco makes the SSR in 35x10.5. Cooper has the new STT Pro is 34.49x10.9.

Nice! Yeah I looked at the TSL also. Hoping to not spend too much but I hope as a camper, I won't shred the tires as bad as I used to. I will probably be buying new wheels to widen the stance a little so I will step up to a 16 or 17 inch wheel for better options. Any recs on basic steel wheels?

Looking forward to the future of this build. I had a 99 GMC Highrider, and I loved that thing. I was young and tore the crap out of it though. Blew one engine and almost another before I got rid of it. I still wish I had it sometimes.

I was young too when I got this one. Got it new in 99 as a high school graduation present. It is pretty well worn in at this point!! Time for a new, stronger, drivetrain. I am also on my 2nd engine.

Spool gun? Curious what setup your using and how you like it?

TIG. They're not all pretty but I am rushing a little. No effect on the strength though. I use an older Miller Dialarc HF 310 amp machine.
 
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Colorado_Outback

Adventurer
TIG. They're not all pretty but I am rushing a little. No effect on the strength though. I use an older Miller Dialarc HF 310 amp machine.

Cool. I do Aluminum GTAW for a living, I'm getting ready to build an aluminum flat bed and need to use a spool gun is why I ask. Looks good, ill be following.
 

javajoe79

Fabricator
Contemplating a lift mechanism now. Thinking acme rods inside a couple tubes to make a home made linear actuator. I found some gearmotors on ebay that have 1/4 HP at 41rpm output speed and draw up to 23 amps each. This should easily lift the roof but by my math it will take 10 minutes with 8 TPI acme thread or about 7 minutes with 6 TPI acme thread.
 

javajoe79

Fabricator
Cool. I do Aluminum GTAW for a living, I'm getting ready to build an aluminum flat bed and need to use a spool gun is why I ask. Looks good, ill be following.

Nice! I am thinking of maybe changing my mounts around to a 3 point setup to keep the truck from twisting the camper box. I am going to do some tests first to see how much flex I get though.
 

javajoe79

Fabricator
More progress. Tail light cutouts and a complete bottom frame section. Making a harness for the lights today.

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mtm_motors

Observer
Enjoying the build, I'm hoping to either scratch build or do a U-Haul conversion in the future so it is some good inspiration.

I'm also intrigued by the English ladies you are keeping company with!
 

J.R.

Observer
echoing mtm_motors: youve got some interesting projects in the background, while your working on your "modest" S10.
 

javajoe79

Fabricator
The silver tube is one of my projects. It's a lakester land speed car that I am building for a customer. It started as an auxiliary fuel tank for an F16. The brit cars are my shop mates customers.
 

javajoe79

Fabricator
More progress..

I got the front fenders in the other day. As you can see from the pics these will allow alot more tire at stock ride height. They are the same amount of flare as the stock ZR2 flares but much bigger opening.

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Here is one of the gear motors that I bought on ebay. They are $400 new!! Got them for $50 each and they are like new. They both output 300 in/lbs each. I ordered some acme rod and nuts and I am going to make some large linear actuators with them. I will need 3' of travel to lift the roof. My plan is to have the front of the roof as the hinge but it will travel in some slots for 1' up. Then once it maxes out the travel in the front it will start lifting the rear of the roof to around a total height of 90" or so from the floor of the main box. Using acme thread to transmit the motion for the gear motor into linear motion will make the whole assembly self locking in that it cant go down or up unless the motors turn. So there will be no need for external latches to hold the roof closed while driving and I can raise the roof without getting out of the truck. So in the event of bad weather when I arrive in camp, I can just hit a switch, climb from the cab, through the rear window opening into the camper and go to sleep.

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I am almost finished with the over cab bed portion too. I will be adding one more tube across it lengthwise. This will fit a queen bed almost entirely over the cab.

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