Joe Michalak
New member
Custom 2015 Aliner Ranger 10 Offroad/Boondockers Special.
There are a huge number of upgrades and modifications to this rig to make it more durable, more functional, more comfortable, and more aesthetic. My goal was to turn the factory unit into something useful, practical, and reliable under regular use; moving it in the direction of a true “expedition” off road camper, but with the added advantages of an indoor kitchen and stand-up interior space, all without canvas. NOTE: This camper is still NOT RATED for heavy-duty off road driving at speed, with its current torsion suspension design, however it is FAR more rugged than its original factory condition. Aftermarket suspension upgrades are available.
This project has been my serious hobby over a 4 ½ year period starting with a new 2015 fully-loaded off-road package from Aliner including: 3000lb axle with torsion suspension and electric brakes, extra ground clearance, diamond plate at front, double propane tanks, 2 skylights, HW heater, furnace, 3-way fridge, Fantastic fan, outside shower, high wind kit. I am hoping to pass this unit on to a seasoned RVer who understands and appreciates the unique advantages of this camper and intends to use it fully. All welding by a highly competent, professional fab shop.
Frame/Suspension:
Added 2” x 3" Box Steel Frame between factory frame and suspension allowing the new floor to be “dropped” a full 7” in the walk-around area, yielding:
* Much stronger camper frame, reducing flex under load. Does not affect final effective ground clearance as the “drop” in the floor system is not full length and the body of the camper has raised 3” from this modification. Larger tires complete the final ground clearance equation.
* Increased stand-up height yields a full 8’ headroom from new "dropped" floor to peak of roof at interior. This mod was a game-changer in the livability of the camper, and no more creaking cabinets when moving around in unit.
* Stronger floor framing with 3/4" plywood over 2"x 2" welded box steel supports 16” oc. Dropping the floor has brought the counter top height to 35" - no stooping over low counters, while improving sightlines out windows and increasing interior spaciousness dramatically. Toe kick space incorporated at sink cabinet side. Two inches exterior-rated foam insulation below entire camper floor for warmth and quiet, totally undercoated, then covered with FRP panel below, except at gas line access.
* New, 6-ply, 15" tires allow for lower tire pressure, better ground clearance; full size matching spare.* Bumper upgrade to 4”x4” tubing. Supports spare tire or bicycles with less flex, stronger frame.
Rebuilt/Lowered Bed Platform yielding:
* 3" more headroom over bed when sitting or sleeping.
* Better sightlines out windows from bed platform.
* Stronger platform framing and connection to body.
* Adjustable platform width for two sizes of mattress.
* Improved layout of storage compartment, plumbing, and electric utilities below bed platform, resulting in much more usable space.
* Added very large HD rollout drawer below platform to allow for storage access even with bed fully extended. Hi capacity, full-extension slides, 36” travel.
* Upgrade foam mattress. 6" dual density. Extra piece allows for full-size double bed.
Electrical System:
* 95 Watt solar panel with 35 amp GoPower Controller. Panel on 25' cable to find the sun; can be mounted on hitch when in camp, or simply set on the ground with its steel frame for stability.
* Dual 6v deep cycle batteries new in 2017
* Several LED light fixtures added for reading, over kitchen area, in cabinets. LED lighting throughout, includ ext porch light.
* Digital thermostat for furnace controls temp within approx. 4 degree variation.
* Cooling fans added at back of fridge increase cooling efficiency, with switch at interior.
* Shore power cord upgraded to exterior plug style to eliminate tangling under bed platform. Eliminates draft at sidewall penetration. Cord storage below bed platform deletion left more room for other utilities below bed.
Custom Shallow Storage Cabinet beside entry door replaces factory unit. This cabinetry is a very important structural component of the trailer box sidewall, as it braces the wall supporting the door - it was weak from the factory and almost useless structurally after the first year. The new cabinet is very strong, integrated into the body/frame, while providing much more storage room. Slide-off/removable table top is part of this design.
New Wood Countertops in several places extend the workspace, strengthens cabinetry and camper body, more aesthetic. Two sections are removable depending on use of the space and for travel. In bed-retracted position (shown), good seating-to-counter arrangement for eating and writing. There is more useable counter top in this camper than most twice it's size.
Water System upgrades:
* Added 2 gallon water pressure tank and check valve so pump cycles less often. Quieter system, pump lasts longer, extra water storage. Approx. 3/4 gallon drawdown between cycles.
* Upgrade water pump is quieter and more powerful. User-friendly service access to plumbing system compared to factory.
* Bypass valve at water heater location for easy winterizing and recharging.
* Marine-grade 100% brass mixing valve with aerator at sink is a joy to use.
* Aftermarket shower head at exterior shower with full shut-off at head conserves water.
Larger, Bonded-style Awning Window beside entry door window replaces factory unit. Better view, more ventilation, especially during rain. This unit is double-pane solar glass.
Custom Glass Skylight with structural aluminum curb at rear replaces rear acrylic skylight bubble. Benefits include ¼” tempered solar glass for undistorted view - durable and washable. Unaffected by UV; a permanent, clear view window over the bed platform. Curb carries weight of glass directly to roof frame while adding support to roof panel. Increased pre-load on roof springs to largely offset weight.
The front skylight has been replaced since these photos were taken, with a new factory acrylic bubble.
Additional Heat Run off furnace along plumbing and into rear plumbing compartment to protect against freeze-up on those cold nights. Heat is better distributed throughout camper; temperature more stabilzed. Added foam insulation at wheel wells.
Additional Hardware connecting roof to sidewalls for high wind protection, reducing drafts, less movement of panels in very windy conditions.
Water Tight Hinged Cover at Exterior Furnace Vent prevents dust and water penetration into rig during travel and at the carwash. Open only when furnace system is going to be used. Prevents insect intrusion into furnace during storage. Safety backup provided if cover is closed as furnace sail switch will not activate; prevents burner lighting.
Reconfigured Fridge Venting System prevents gas flame blowout, more efficient cooling; adds plumbing freeze protection.
New Propane bottle cover since photos taken. Extra shelving and interior cabinet dividers maximizes cabinet strength and storage. Removable Carpet over pad at floor replaces factory vinyl.
Brakes checked, bearings repacked at 12,000 miles.
Furnace cleaned and sail switch replaced. Furnace circuit board replaced with upgrade "dinosaur" board.
New automatic changeover gas valve at propane bottle.
Exterior has been kept waxed.
Factory dry weight was listed as 1470 lbs new. I probably added 400 to 500 to that weight. Have all manuals
Asking $16,000 for this camper. This unit is VERY quick to set up, rugged in a storm, solid-sided against bears, and extremely easy to tow. Excellent livability for a camper this size. More can always be done, but it is ready to go as is, and very capable.
There are a huge number of upgrades and modifications to this rig to make it more durable, more functional, more comfortable, and more aesthetic. My goal was to turn the factory unit into something useful, practical, and reliable under regular use; moving it in the direction of a true “expedition” off road camper, but with the added advantages of an indoor kitchen and stand-up interior space, all without canvas. NOTE: This camper is still NOT RATED for heavy-duty off road driving at speed, with its current torsion suspension design, however it is FAR more rugged than its original factory condition. Aftermarket suspension upgrades are available.
This project has been my serious hobby over a 4 ½ year period starting with a new 2015 fully-loaded off-road package from Aliner including: 3000lb axle with torsion suspension and electric brakes, extra ground clearance, diamond plate at front, double propane tanks, 2 skylights, HW heater, furnace, 3-way fridge, Fantastic fan, outside shower, high wind kit. I am hoping to pass this unit on to a seasoned RVer who understands and appreciates the unique advantages of this camper and intends to use it fully. All welding by a highly competent, professional fab shop.
Frame/Suspension:
Added 2” x 3" Box Steel Frame between factory frame and suspension allowing the new floor to be “dropped” a full 7” in the walk-around area, yielding:
* Much stronger camper frame, reducing flex under load. Does not affect final effective ground clearance as the “drop” in the floor system is not full length and the body of the camper has raised 3” from this modification. Larger tires complete the final ground clearance equation.
* Increased stand-up height yields a full 8’ headroom from new "dropped" floor to peak of roof at interior. This mod was a game-changer in the livability of the camper, and no more creaking cabinets when moving around in unit.
* Stronger floor framing with 3/4" plywood over 2"x 2" welded box steel supports 16” oc. Dropping the floor has brought the counter top height to 35" - no stooping over low counters, while improving sightlines out windows and increasing interior spaciousness dramatically. Toe kick space incorporated at sink cabinet side. Two inches exterior-rated foam insulation below entire camper floor for warmth and quiet, totally undercoated, then covered with FRP panel below, except at gas line access.
* New, 6-ply, 15" tires allow for lower tire pressure, better ground clearance; full size matching spare.* Bumper upgrade to 4”x4” tubing. Supports spare tire or bicycles with less flex, stronger frame.
Rebuilt/Lowered Bed Platform yielding:
* 3" more headroom over bed when sitting or sleeping.
* Better sightlines out windows from bed platform.
* Stronger platform framing and connection to body.
* Adjustable platform width for two sizes of mattress.
* Improved layout of storage compartment, plumbing, and electric utilities below bed platform, resulting in much more usable space.
* Added very large HD rollout drawer below platform to allow for storage access even with bed fully extended. Hi capacity, full-extension slides, 36” travel.
* Upgrade foam mattress. 6" dual density. Extra piece allows for full-size double bed.
Electrical System:
* 95 Watt solar panel with 35 amp GoPower Controller. Panel on 25' cable to find the sun; can be mounted on hitch when in camp, or simply set on the ground with its steel frame for stability.
* Dual 6v deep cycle batteries new in 2017
* Several LED light fixtures added for reading, over kitchen area, in cabinets. LED lighting throughout, includ ext porch light.
* Digital thermostat for furnace controls temp within approx. 4 degree variation.
* Cooling fans added at back of fridge increase cooling efficiency, with switch at interior.
* Shore power cord upgraded to exterior plug style to eliminate tangling under bed platform. Eliminates draft at sidewall penetration. Cord storage below bed platform deletion left more room for other utilities below bed.
Custom Shallow Storage Cabinet beside entry door replaces factory unit. This cabinetry is a very important structural component of the trailer box sidewall, as it braces the wall supporting the door - it was weak from the factory and almost useless structurally after the first year. The new cabinet is very strong, integrated into the body/frame, while providing much more storage room. Slide-off/removable table top is part of this design.
New Wood Countertops in several places extend the workspace, strengthens cabinetry and camper body, more aesthetic. Two sections are removable depending on use of the space and for travel. In bed-retracted position (shown), good seating-to-counter arrangement for eating and writing. There is more useable counter top in this camper than most twice it's size.
Water System upgrades:
* Added 2 gallon water pressure tank and check valve so pump cycles less often. Quieter system, pump lasts longer, extra water storage. Approx. 3/4 gallon drawdown between cycles.
* Upgrade water pump is quieter and more powerful. User-friendly service access to plumbing system compared to factory.
* Bypass valve at water heater location for easy winterizing and recharging.
* Marine-grade 100% brass mixing valve with aerator at sink is a joy to use.
* Aftermarket shower head at exterior shower with full shut-off at head conserves water.
Larger, Bonded-style Awning Window beside entry door window replaces factory unit. Better view, more ventilation, especially during rain. This unit is double-pane solar glass.
Custom Glass Skylight with structural aluminum curb at rear replaces rear acrylic skylight bubble. Benefits include ¼” tempered solar glass for undistorted view - durable and washable. Unaffected by UV; a permanent, clear view window over the bed platform. Curb carries weight of glass directly to roof frame while adding support to roof panel. Increased pre-load on roof springs to largely offset weight.
The front skylight has been replaced since these photos were taken, with a new factory acrylic bubble.
Additional Heat Run off furnace along plumbing and into rear plumbing compartment to protect against freeze-up on those cold nights. Heat is better distributed throughout camper; temperature more stabilzed. Added foam insulation at wheel wells.
Additional Hardware connecting roof to sidewalls for high wind protection, reducing drafts, less movement of panels in very windy conditions.
Water Tight Hinged Cover at Exterior Furnace Vent prevents dust and water penetration into rig during travel and at the carwash. Open only when furnace system is going to be used. Prevents insect intrusion into furnace during storage. Safety backup provided if cover is closed as furnace sail switch will not activate; prevents burner lighting.
Reconfigured Fridge Venting System prevents gas flame blowout, more efficient cooling; adds plumbing freeze protection.
New Propane bottle cover since photos taken. Extra shelving and interior cabinet dividers maximizes cabinet strength and storage. Removable Carpet over pad at floor replaces factory vinyl.
Brakes checked, bearings repacked at 12,000 miles.
Furnace cleaned and sail switch replaced. Furnace circuit board replaced with upgrade "dinosaur" board.
New automatic changeover gas valve at propane bottle.
Exterior has been kept waxed.
Factory dry weight was listed as 1470 lbs new. I probably added 400 to 500 to that weight. Have all manuals
Asking $16,000 for this camper. This unit is VERY quick to set up, rugged in a storm, solid-sided against bears, and extremely easy to tow. Excellent livability for a camper this size. More can always be done, but it is ready to go as is, and very capable.
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