My crew cab IDI Alaskan Camper build

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This has been a decision that has taken me a long time to make. After finally realizing that there is not nor ever will be one single vehicle that suits all my needs I had to make some compromises. In the long run I need something that both my family and I could take exploring for long periods of time and still be able to drive some somewhat difficult trails in poor weather conditions. While many vehicles can do all this and much more there are a few items that I needed in specific that really narrowed down my search. Here is a list of things I needed when I was searching for my last truck.

4doors—must have.

Ability to tow a large load safely

Manual transmission

Simple engine design (mechanical injection or Carburetor)

Cost less than $7K and model had to have a long production run.

Strong drive train.

Ability to carry a Camper. (Alaskan, Flipac or just my RTT)

Return 15mpg or better unloaded.

Minimum 450+ mile range on stock fuel system.

Truck: What I ended up with was a crew cab 1991 Ford F350 with the mechanically injected 7.3 IDI International diesel engine and a ZF 5speed transmission. This truck has the solid Dana 60 in the front along with a Sterling rear axle both with 4.10 gearing. I have owned several IDI Ford diesels and although they have some quirks they prove to be extremely reliable and durable—they are built to work hard. I like these because they require one wire to run, will burn many different fuels and because Ford sold so many F-series trucks these years and International sold so many engines parts for both are very common and not too expensive.






Camper: Although I have wanted one for quite awhile this Alaskan fell into my hands much sooner than I had anticipated. It is a 1971 Fiberglass Alaskan 8’. Aside from it being 40 years old it is in very good shape and still has the features that make Alaskan’s desirable. Strong construction, pop top and very thick insulation make these great for backcountry exploring and cold weather camping. They weigh in at ~1100 lbs.





Plans-short term: For now there are a lot of modifications I need to do to the wiring and heating so I’m going to start with the needed items and work my way into accessories. I am hoping to have the heater and stove working and the water system working in time for April. The truck needs new tires too so I’m leaning towards BGF KM2 255/85E 10ply’s.

Goals short term: In April we are going through the San Rafael Swell down to Arches and my wife hasn’t ever been to So. Utah so this should be a lot of fun. We also have many local camping trips planned this summer along with a trip to Yellowstone/Grey’s river area.

Plans-long term:

Onboard air. I’ll probably go electric on this one.

Solar DC charge system. I am not going to tie the camper power in with the
truck which means I have no easy way to charge the batteries while out and about. The truck needs all the power it can get from the two batteries it has just to crank the engine over so I don’t want to take away from that.

Lockers in both axles. Detroit rear selectable front.

Sliders (really really long sliders).

Winch/winch bumper. 12K lb or higher. Aftermarket bumpers are big $$$ so
I’ll try to build and mimic an ARB Bull Bar when I get the time.

Low profile flat bed. These just work so good with off-road campers. I could put all my air tanks, propane and other things under the platform up and out of the way.

Modify departure angle. I already removed the spare tire and brackets now I need to do something with the rear bumper and receiver hitch. May install a non step bumper from a bronco and see how that works out for a quick fix.

Goals long term. Although my last trip fell through I still want to tour Alaska bad—really really bad. Maybe one day I can make it up that way.

Anyway I don’t expect this to be a quick buildup by any means, but I will post up any progress as it comes

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This week I'm hoping to pull down the bulky AC unit and plumb in my propane tank under the truck bed. I can't think of a time when I would ever need AC and this thing is just way too big

[Sock Puppet]

Excellent choice and a great project! I would also consider having the camper battery tied into the truck's charging system with a marine battery switch. This would allow you to charge your camper battery while traveling, and isolate it when starting the truck.

[Rot Box]

Thanks for the reply!

I explored my solar charge system idea with a friend at work tonight (His house is completely solar powered ) and quickly determined it is just not cost effective for what I plan to do. Great idea on the isolator that will probably be my best bet for sure.

I'm still kind of new to the camper thing but I'm really getting some great ideas searching around on Expo. Anyway I guess me saying build was a bit of an exaggeration, but I'm sure having fun--can't wait to try it out

[ntsqd]

The problem with the marine switch is that is keeps the batteries in parallel all of the time. Running down your house battery(ies) will also run down your starting battery(ies). There are a lot of automatic options available. Fortunately we have this resource: http://www.expeditionportal.com/foru...splay.php?f=48

[MATTY291]

Looking forward to this build. Nice truck & very cool camper!!

[adi]

I had thoughts of putting the KM2's Load Range E on my truck, but the lack of pretty much any other LR E tires in that size, and the limited availability of even the KM2's really pushed me to more common sizes (especially for E/10 ply). You have a lot more options with 235/85, 265/85, and 285/75. Just my own thoughts on E range tires, looking forward to seeing this get built up.

(i.e. 255/85 shows less than 5 available on tirerack, 235/85 and 285/75 KM2's are available everywhere)

[WKCwith5]

Great truck. I to have debated along time on the right truck. I have chosen this same truck for the same reasons. I am considering a Cummins swap in the future. But for now just going to work on getting all the axels, brakes and other wear items up to top notch order. Looking forward to your build.

[Rot Box]

Thanks for all the reply's you guy's

You have a lot more options with 235/85, 265/85, and 285/75. Just my own thoughts on E range tires, looking forward to seeing this get built up.

That's what I'm starting to realize I'm not going to pull the trigger for a few more weeks, but I am really starting to have second thoughts about the KM2's altogether.

I am considering a Cummins swap in the future. But for now just going to work on getting all the axels, brakes and other wear items up to top notch order. Looking forward to your build.

I actually bought this truck planning on the Cummin's swap with a VE (rotary) pump. I LOVE that combo even more than the P pump it just works so well. The thing that the IDI has going for it is the 83-94 year run (6.9/7.3) and finding a replacement engine in good shape for less than $500 is not hard at all.

Here are a few swaps that I was involved in. Both are my brothers trucks--85 F350 crew cab and 91 GM 1500 with dana 60 front axle.

The GM had an NV4500 5 speed and so did the P-pump 5.9 Dodge donor truck so that made the swap was much easier.

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The Ford actually has a school bus 6bt with the C6 that came on it from the factory. Note the water to air intercooler

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Good times!

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I have to apologize as my computer skills are very lacking and I somehow managed to crash my Photobucket account and lost the pics of the camper on the truck.... I restored most of my other pics though... What a nightmare

Anyway I routed in a connection for my propane tank today. I have a horizontal cylinder that mounts under the bed that I thought about using, but I declined that idea in favor of a portable 5lb cylinder. It will be much easier than a stationary setup and will come in handy if I decide to cook on a Camp Chef. More on that tomorrow for now I really need some sleep