out with the old in with the new

westyss

Explorer
Hi all , starting a thread on my new camper. I had a 91 westy with lots of mods; suby, engine, propex furnace , dual propane tanks etc, and we slowly have grown out of it. So after lots of looking around with not alot of options, I chose to go with the FG. My main needs or wants were , bigger, able to haul more, and 4x4. I had a pretty good idea of the issues with the FG and thought I could work around them. I have just completed my first big trip with it and am very happy with it except improving the ability to dampen big bumps. This first pic is when I bought the truck and got it home. It was new but was on a lot for a while. Its a 2007 that I purchased in 2009.
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The first thing needed was a deck, so I mocked one up out of wood. My neighbors thought it was to be built out of wood, ha.

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this is in its semi complete state, still need to complete the interior and heat/ water system storage areas, and an out door kitchen. I needed to use it so am taking a break from working on it. It has some temporary cabinets, a queen size bed, and a 6.8 cu/ft nova cool 12 volt fridge with freezer. I do alot of highway so the bulk of my driving is with that in mind, but needed to be able to get into those hard to get into places. I have gotten stuck several times with my 2 wheel drive westy. Our trip was a good distance, 8,225 km with some 4x4 ing , I like the FG for its size and great turning radius, we got our selves onto an ATV track that dwindled down to nothing and did a reverse turn in very little space, Once off the track I had to remove some foliage that we took with us.
I will try to post some pics of the on going construction. Yves

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westyss

Explorer
deck

After finalizing the plans for the deck I had some one make it, I left the top off the deck to finish the mounts easier

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Then a little testing, without any weight the frame flexes alot, but gave me a good idea how much movement it had.


This next pic was with the duellies still on.



Singles on , top of deck on


 
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westyss

Explorer
cabin

I had the cabin pieces made from my plans and once they were ready I took the FG to pick them up. Just a little snow.



The walls are fiberglass each side with a high density foam filled honey comb structure, strong like crazy. You can see that in the lower pic.With a bunch of aluminum I started to asemble it. The cabin is a complete unit, walls roof floor. Basically like a funny shaped shoe box.



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westyss

Explorer
time out

thats it for now til next week, I have to drag myself out to this place for some fly fishing.

 

LukeH

Adventurer
thats it for now til next week, I have to drag myself out to this place for some fly fishing.
What a chore, to have to go out fly fishing :ylsmoke:

Looks fantastic, looking forward to the next installment.
It appears that you've mastered quite a few of the issues both specific to FGs and those generic to a 4x4 lorry build. I'll be interested in the poptop sealing particularly.
Thanks for sharing :)
 

1leglance

2007 Expedition Trophy Champion, Overland Certifie
great job and I am looking forward to hearing more...
I assume this is setup for 2 people but just wanted to make sure.
 

spencyg

This Space For Rent
Such a Tease.

Strong work so far. Interested to see the interior and details on your lift mechanism.
 

Bike_Mech

Adventurer
Is that NidaCore for the walls, roof, and floor? If so what thicknesses are you using, it looks like a couple sizes?

Thanks
-Chris
 

westyss

Explorer
walls

Thanks for all the comments, to answer a couple of questions; Yes its for 2 people and a dog, I removed the third seat and installed 2 national air seats.
;The top to bottom seal is done with brushes, Fuller Brush Co.
;Its not Nida Core, its a composit made in British Columbia to specific sizes.
; The lift is done with 400 pound 12 volt 18" actuators.

So after setting the floor down I set aluminum dowels in the floor to line up the walls and semi hold them in place. This I was hoping to provide lateral strength, but mostly to line up the walls because I was working alone and I used Sika 252, and you dont have much time to work with it. The whole concept was to have a self supported structure, no frame, the walls are the strength.

you can see a bit of the honey comb in this pic, far wall.

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I assembled all the walls in place, then finished sticking the step floor in place.

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note the holes for the dowels

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After levelling and aligning the walls I drove long screws into the foam-honeycomb stuff, and surprisingly it grabbed and sucked together really well.
I wanted to have the whole structure sound and ready for aluminum corners, as that was what holds it all together.

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westyss

Explorer
walls

With the walls looking OK I got ready for the aluminum corners.

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As much as possible I had all the corners cut and fit prior to starting the Sika process, and that was a little more complicated than anticipated, I had to allow for 2mm of space for the Sika, ( I think it was 2mm, might have been more)

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I dont have any pics of me mounting the aluminum with Sika, I was mostly running around like a chicken with his head cut off trying to get the aluminum pieces in the right spot. I used jacks, 2x4's, shims and all sorts of things to coerce the stuff into place, like I said you dont have much time to work with it.
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westyss

Explorer
mock

With all the aluminum in place I had a box, a funny shaped box.

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At this time in the build I decided to do a poor interior mock up to see if my plans would work out, I used google sketch for my plans, works good.

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The point was to make sure the space was Ok for the kitchen/ washroom area, I also mocked up the bed/sitting area, I had my wife have a look and it seemed OK.
Some funny things; once the box was made, I clambered into it and almost passed out, the fumes were all collecting inside with no where to go, I had to put the fan in there pointing up to ventilate. Also , no door!! getting into the box needed 2 ladders, one inside and one outside and climb over the sides, that is a pain in the a**.

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