Isuzu NPR HD Truck Camper Build

[VicHanson]

It's not a fancy fridge, just plain basic model, no digital controls. I checked on their website and the downloadable manual there doesn't say anything about inverters or RV use. On some other models it does, on some it doesn't. My guess is that they put that in there just for product liability protection, not sure if they are adding it or taking it out of their manuals.

It only draws 1 amp if I remember right, 290 KW per year according to the yellow energy tag.

I sent them a mail to customer service, and it was rejected - mailbox full !! Guess I will need to call them.

[VicHanson]

I bought a bunch of 1x2, 1x3 and 1x4 today, and started cutting them to replace the bad wood. Will put them in with Liquid Nails adhesive, and I think staples, like was done at the factory. Too hard to use screws with the inside paneling on. Feels good to be starting on putting it together, instead of tearing it apart!

[john101477]

pics or it didn't happen lol
I have been watching intently and reading along. would love to see your preperations as you go. As i stated earlier, I also own an 01 NPR flatbed. I figure if i can't sell the dang thing i might as well use it

[VicHanson]

I was hoping to get lots of work done on the camper today, but spent most of the day running around shopping. I put the first new board on this morning, but the staples I had were one inch in length, and they should be 5/8". I went looking for some, and finally found them at a builder's supply store - $88 for a box of 10,000! After a few other stops, I found them for about $30, but still a box of 10,000. I probably should have gotten them, but will see if I can a smaller box, only need a couple of hundred.

I bought some more lumber, including the plywood for the flat bed, finally decided to go with treated, after much debate. I was also looking for a truck parts store for filters last night by Internet, and found another Isuzu truck dealer, they also sell Fuso and Hino. I went there today to see if they would buy the truck body. They offered me $1000 and they would remove it. I explained that I was going to have the flatbed builder prepare it for removal and asked if they would give me $1100, which they agreed to. So on Tuesday, I will take it there and they said they would have my check ready, and take the bed off!

I also looked at the refrigerator again at Home Depot, and the price had gone up $20. I asked when that happened so the salesman checked the computer and it still showed $199 there, so he said he would sell it for that. But when he went to get one they didn't have any in stock, so I asked about the floor model, and he gave me that with a $25 discount.

The sticker on the back says it draws 1.5 amps and the yellow label says 290 KW per year. I bought a Kill a Watt meter so see what it uses and after it got cold, in 2 hours it has used less than .04 KW (still shows .03 so it is between .03 and .04). 290 KW per year equals just under .8 KW per day or .033 per hour, so it is very efficient! It is almost silent as well, which is important when it is just a few feet from my bed. I'll check it again after 24 hours and then after a few days to get a more exact reading, but I should have plenty of solar power to run that. It is a bit of a $200 gamble to see if it will work OK with the inverter, but life is full of uncertainties!

OK John, a few pics! Two 'before' photos and one of the first new board! Didn't get anything more done on it today.
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[VicHanson]

Forgot to mention one thing - I filled with fuel yesterday after a week of city driving, took 11.76 gallons for 180 miles, so 15.3 mpg. I am much happier with that than the 11.5 last time. I was driving very gently.

[1speed]

...OK John, a few pics! Two 'before' photos and one of the first new board! Didn't get anything more done on it today.
IMGP0125_resize.JPG IMGP0130_resize.JPG IMGP0135_resize.JPG

Holy ! Talk about a project.

Still think you'll be gone by the time I get back from the Expo?

[john101477]

wow lots to do but it will be worth it

[VicHanson]

First some good news about the fridge, it only used .42 KW in the first 24 hours, according to the published rating, it should have used .79, so it is much more efficient than stated. I finally found out how to change it to get the current amp usage, but then I couldn't find it running all day. Every time I went by it to check it, it wasn't running. Finally caught it running a few hours ago, it was showing 1.08 amps, but as I stayed and watched it, it slowly dropped down to .96 before it shut off. It uses .08 amps in standby.

I made some good progress on the camper today, in spite of spending lots of time thinking and checking to make sure I was doing it right. I put some of the smaller pieces together on a table, that way I could staple it on both sides, as well as it would have been difficult to do it in place because there wasn't anything behind to support the pieces. I also replaced some of the 1x2 pieces with 1x4, because it was easier to tie the pieces together. Here are a few of the latest pictures.

Oh, I was able to use the 1" staples for many areas, and was able to cut some of them shorter to use where the 1" ones were too long.

Vic

[VicHanson]

Jim, I could still be here when you get back at the way things are going now!

Peter, thanks for reminding me about the epoxy to rebuild the weak wood, I will try to get some right away.

[VicHanson]

Peter, If I'm understanding you correctly, you are talking about the shelf plywood, meaning the flat plywood under the wide portion that would be above the side of the pickup in normal use. On the driver's side, that was rotten on the outside the full length of the camper. The worst place was where the water inlets were, both to fill the tank and the city water, so something must have been leaking there. I cut out the whole piece of plywood and am replacing it. Much of the inner skin plywood is gone, all that is left is one layer of plywood and the vinyl inner coating. To replace that would have been a major problem so I am leaving that in place, I will bond it to the ridgid foam insulation, but it won't be contributing any structual strength (it was only 1/8" to begin with). The 5mm Lauan plywood will go over that, also attached with Liquid Nails adhesive, as well as stapled to the wood framework. I am planning on using Thompson's wood sealer on the plywood. I will put the original aluminum siding back on over this. Any advice on the best type of sealer to use for the seams and joints on the aluminum siding? I have heard there is a roll of putty type sealer, or the caulk gun type.

Yes, the garage will be structually attached to the bed overhang, so it won't be supporting itself anymore. Also I will be building storage areas under the side shelves, they will be resting on, and attached to the plywood decking of the new flatbed. Still not sure exactly how I will do the doors, I have a quote from the flatbed builder, but it's quite expensive (about $750), so will be doing something cheaper with wood, not aluminum.