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off road camper


 
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joe lane
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Joined: 28 Jun 2009
Posts: 138
Location: COVENTRY ENGLAND

PostPosted: Fri Nov 29, 2013 11:12    Post subject: off road camper Reply with quote

hi all,   long time no hear,

right im away some weekends green laning/wild camping/billing/  and plan to stay away for a week in the lake district so after a bit of research im going to build an off road camper  around the teardrop idea but i am not following the same shape.
so starting from the bottom up
i have been looking a various trailers from sankey to farm trailers or even specialist,  then i went looking at japanese axles from other trucks so i could keep the same stud pattern ( land cruiser axles are to expensive )  these were all to narrow, then i found the nissan navara with a tubular beam instead of the same old cast beam
now my idea was to cut the center diff out and sleeve it to the required width,  i picked up an axle and set about cutting,  then realized the half shafts will need to be supported in the existing axle tube.  
i will have some pics to support my endeavours,    which i will post asap
catch you all later   joe
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PostPosted: Fri Nov 29, 2013 11:12    Post subject: Google Ads keep this community free to join!


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watkinsontj
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Joined: 20 May 2004
Posts: 74
Location: Chessington, Surrey

PostPosted: Fri Nov 29, 2013 15:16    Post subject: Reply with quote

Hi Joe,
Do you need the half shafts? On my 80 they only give the drive from the diff to the hub and help keep the oil in the axel.
You may find the hubs will be ok with out the half shafts. Not quite sure about the Nivanna set up though.

Good luck with your project.
Tim.
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joe lane
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Joined: 28 Jun 2009
Posts: 138
Location: COVENTRY ENGLAND

PostPosted: Sat Nov 30, 2013 21:28    Post subject: camper Reply with quote

hi  tim,  yes , the way the shaft is setup on the navara makes it impossible, there is only one bearing in the hub end it does seem a strong fit but im not going to take the chance,  got my pics soughted out now so im going to show,    i have been very busy,      catch you later tim
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joe lane
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Joined: 28 Jun 2009
Posts: 138
Location: COVENTRY ENGLAND

PostPosted: Sat Nov 30, 2013 22:26    Post subject: camper Reply with quote

hello all,   right first off im not happy calling this project a camper, a teardrop, i dont no what to call it  lol we shall see

well i have now shrunk all the pics of the build so far and now im going to try and post   here go'es
[img][/img]
this is the axle cut open the shaft floats so i had to sought out a bearing, and that is not that easy i tell you, the nearest i could get hold off was a 32mm internal  the shaft is 33.75mm  so strip and shave in the little lathe    this will get some laughs
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bearing fitted and the excess cut off, now its ready for the outer sleeve
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im kinda lucky my brother in laws a great welder
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just to give us a bit of strength i drill some 16mm holes in the side and then welded them up to the axle tube,  i also fitted an an oil plug,  im going to half fill with oil as the bearings are open face

[img]http://[/img]
this is the finished axle  the same track as my 80 series
now to the chassie  which is basically  a 4x2 box section  finished at 2.4 x 1.2  then out to around 1.9 at the out-riggers  soughted out the mounts
bit of steel tube braced and a kinky set of welded leaf mounts  4mm thick

[img]http://[/img][img]http://[/img]
sorry about that,  2nd glass of wine

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thats the mounts done now the a frame, this is easy to setup with a laser clamped to center of the chassie no string line to get in the way
my a frame might be a little on the heavy side  100mm x 100mm x 6mm  angle iron  but beggers cant be choosers it was free
[img]http://[/img]

as you can see im using the bradley  hitch with the override damper so i can still use the axle breaks  we set this upside down just to make sure every thing is lined up when welding
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laser setup
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forgot to mention i used some old 12mm x 125mm bolts for the shock mounts, which we welded them up floor, were not sure how this thing will sit yet,,  the axle is suppose to be good for 1 ton

during a rough measure my truck sat 690mm to center of the nato hitch bolt pattern on the rear of my truck
my next job is to weld on the out riggers do the reversing brake while the chassie is open  then  paint in hammerite (black)
this is not the first time we have built some thing together we have numerous projects under us   he supplies the welding and i supply the good looks
catch you later    joe
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watkinsontj
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Joined: 20 May 2004
Posts: 74
Location: Chessington, Surrey

PostPosted: Thu Dec 05, 2013 14:06    Post subject: Reply with quote

Hi Joe,
Looks like you are getting things sorted out OK. Your build is comming along nicely. I would love to have a proper workshop with lathes etc, there is so much I could do then.

Good luck
Tim.
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joe lane
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Joined: 28 Jun 2009
Posts: 138
Location: COVENTRY ENGLAND

PostPosted: Tue Dec 10, 2013 23:33    Post subject: off road camper Reply with quote

hi all, just an update  the chassis is now finished and im now ready to start the woodwork,  some pics for you all
this is the hand brake/ reversing brake,  used the original cable and mounts and fitted the the frame then this was extended with 6mm threaded bar with an adjuster in line,  the lever was off set so it pulls the brake cable square-ish

[img]http://[/img]

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i picked up a farm trailer jack leg,  not to happy with it as there is still a bit of movement,  but will do for now
[img]http://[/img]

now the welding is done it was time to paint in black hammer rite, got to say it always gives a good finish,  looks good
[img]http://[/img]

[img]http://[/img]

thats your lot,  now to start the woodwork.   catch you all later

ps:  hi tim,    i dont no how we managed before we had a lathe, we cant seem to do without it now,   some thing else thats very handy at the moment is the home made log burner we built out of an old lpg tank,   keeps the place warm on these cold nights
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joe lane
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Joined: 28 Jun 2009
Posts: 138
Location: COVENTRY ENGLAND

PostPosted: Sun Dec 15, 2013 10:23    Post subject: re: camper Reply with quote

hi all,  
right im guilty of missing a few pics of the underside painted in a waterproof coating made by dunlop
we built the floor using 65mm x 40mm  frame, glued then screwed to a 6mm marine ply sheet,  we used three sheets due to the width




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a great bit of aussie kit

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we have used a 50mm insulation in the floor,  then a 12mm sheet of marine ply fitted to the top  the whole base is bolted down with 70mm tech screws,  i have an underslung water tank to fit under there some where , not sure untill the tank is delivered and see what we are up against,
the next part as i see it is to fit the side elevations these are 18mm marine ply 10x5ft  sheets im only using 9ft x 5ft then the profile is shaped.
the bedding area should be around 2mts x 1.4  then a kitchen in the rear in true teardrop style.  thats all for now see you all later
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joe lane
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Joined: 28 Jun 2009
Posts: 138
Location: COVENTRY ENGLAND

PostPosted: Sun Dec 22, 2013 12:04    Post subject: off road camper Reply with quote

good morning,  

right i have not been near the computer for a couple of days, so this is a catch up.

we spend an average of 2 hours per evening and maybe a day over the week end, we both have other things happening in the back ground.
in my opinion i think this build is comeing along at a pace,  i did gather as many of the materials as possible to save time.
As this has never been down on paper  things do change,  i wanted to build out to the outside tyre wall,  we checked this out before commitment,  so sitting in the drivers seat of my 80 we mocked up the camper at the rear and we could not see the rear end in the mirrors so we reduced it by 50mm both sides and now im happy.  this has been a constent excercise through the whole process.
Now the woodwork has started were both getting excited and things might be happening a bit quicker so there are going to be mistakes, i will hold my hand up for one,  cutting a length of 2 1/2 x 1 three times to get it right was not major as we got plenty of spare so cutting the opening for the door did slow us down a small bit,  well its in now anyway so it will stay there,   lol      well some pics for you all,   please if you have any questions fire away i will get back to you.

[img]http://[/img]
the sides just to remind you 10 x 5  18mm marine ply  i do have a habit of mixing  imperial and metric  just bear with me on that.   the floor has been covered in a 12mm marine ply glued then screwed
the square we used is from a previous build

[img][/img]
the front has been cut back at 45 degrees for a window or skylight

[img]http://[/img]

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this is a scary bit, its to tall,  the brother in law says its not, i think it is

[img][/img]
this is a must when building,  a pocket hole jig, the pics will explane
[img][/img]
the roof joists are drilled twice on one side and once on the opposite then a dab of glue,  they dont come off after,  6 holes per joist is time consuming,  and now i know i dont like the glueing process,   get out the gloves,   the timbers are at 300mm centers so i can use the roof to carry boats and other bits and pieces.


[img][/img]


some of you might have guessed i have missed some pics,  you will now see a bulk head fitted this is a framed / insulated/ ply sandwich  this is between the sleeping area and the kitchen galley

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and now the fitting of the door,  this has happened at this point because we need to insulate the interior walls and build a frame around it,  the doors were from a lady in stoke who custom builds campers from vw vans.

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this door is 1150 x .900mm   and i know its large but the price off these things will scare you and these were cheap because they were big, there is a fine market now for anything to do with teardrop caravans and self builds

[img][/img]

im really please the way the door fitted, we discussed which way to open  we didnt want any leaks so it ended up against the flow if you no what i mean,   the door is only fitted now to build the interior then its removed and fitted later after painting

im using aluminium for the out skin on the roof / front / and the rear which have been ordered in anodized blue at 1mm thick  
the water tank has turned up,  the door locks, i have an 80 litre fridge ready to fit ,   need to find a propane water heater, there are loads on the internet and most are chinese origin cheap and chearfull,  i have me eye on some thing like a morco, paloma, or a valliant these dont need 240v  and a surflow pump that switches on when you demand ,   i have a bit of home work to get through,
if any one out there has any more ideas  let me no,   oh and im fitting solar panels  and two batteries thats more home work,  have had just a brief read through the forums and i think 160watt panels are enough to run a couple of leds , ipad, phone chargers, pump, fridge,   there might be one or two additions

catch you all soon,    and merry xmas to you all
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