oledirteh
Well-Known Member
that commanche though..... drool
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4500 Camper/Jeep Hauler Build
- Thread starter gprguy
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- 4500 camper chassis cab jeep
gprguy
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I'm reeaaaaly looking forward to getting to work on that thing, once the truck is on the road again. It's been sitting there since Christmas. Pretty sure it just needs a new fuel pump or associated wiring and then a brake job.
gprguy
Well-Known Member
Last bracket is done, and all the brackets are welded to the bed now. Look ma - no clamps!
Next up is the 5th wheel mount, followed by the spare tires mount.
Next up is the 5th wheel mount, followed by the spare tires mount.
Spare tire mount is going to be interesting to see. Still planning on going upfront with them?
gprguy
Well-Known Member
That's the plan, I haven't come up with a better idea yet. I have a 10x225" spare tire plate cut out on the CNC plasma, and once I get the 5th wheel rails in I'm going to start hacking chunks out of that front corner. In hindsight I think it's a pretty good option actually. Not if it were a general purpose flatbed, but for a camper like this - it's taking advantage of the available space.
McHenry2500
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Looking Great!
Any plans for taillights yet?
Any plans for taillights yet?
gprguy
Well-Known Member
Thanks! The plan is to do an entire tailboard to enclose the back of the frame and flow into the hitch somewhat. I have a lot to mount back there - taillights, trailer wiring, trailer camera connections, backup camera, park sense, license plate.. But I am going to punt and move that to "phase 2" this coming winter. For now I am most likely just going to temporarily mount the stock taillights under the back there somewhere to get on the road.
gprguy
Well-Known Member
Two long days of laboring away cutting, grinding, drilling - all to shape the 8" C channel 5th wheel mounts so they countersink down into the frame the appropriate amount.
This involved taking 1.5" off the web on one side (the bottom side as it's clamped here) and then the 4 notches along the top side. Lots of shavings..
Here's what one looks like, not fully fit yet however.
And both in place after some final trimming and fitting.
And here's the point of it all with some mock up pieces.
The deck will have 1" square aluminum tube fore and aft with deck boards going side to side.
Once everything is bolted down firm it will be basically flush.
Tomorrow I need to pick up some 1/2" thick bar to make some spacers and then start drilling the holes for the 5th wheel rails.
This involved taking 1.5" off the web on one side (the bottom side as it's clamped here) and then the 4 notches along the top side. Lots of shavings..
Here's what one looks like, not fully fit yet however.
And both in place after some final trimming and fitting.
And here's the point of it all with some mock up pieces.
The deck will have 1" square aluminum tube fore and aft with deck boards going side to side.
Once everything is bolted down firm it will be basically flush.
Tomorrow I need to pick up some 1/2" thick bar to make some spacers and then start drilling the holes for the 5th wheel rails.
gprguy
Well-Known Member
Picked up some 1/2" x 3" flat bar to fill in the underside of the C channel where it sits on the thicker part of the flatbed frame. This means at least above the rails it will be solid steel all the way down to the frame rail under the 5th wheel rails.
A few stitch welds should be plenty since all the loads will be compressive.
The next task that I am not looking forward to is drilling the 20 1/2" holes to bolt the rails down.
A few stitch welds should be plenty since all the loads will be compressive.
The next task that I am not looking forward to is drilling the 20 1/2" holes to bolt the rails down.
gprguy
Well-Known Member
Unfortunately the last week was more or less a loss, had to take a business trip and no progress was made on the truck. But today, let's get back at it.
As I said, the next step was to drill 20 1/2" holes through about 1/4" plate. That sounds like a pain, so let's break out the cheat code - a mag drill and an annular cutter.
Love these things, they go through steel like butter. Here's one of the rails drilled with the bolts test fit in the holes I plan to use.
Clamped in place so I can tack it:
Tacked, and lining up the front mount both by measurement as well as using an actual hitch.
Lather, rinse, repeat for the front mount.
And then some final test fitting after the clamps are off.
All good. Tomorrow morning before it gets warm I'll finish weld them, and then start on building parts for the tire carrier.
As I said, the next step was to drill 20 1/2" holes through about 1/4" plate. That sounds like a pain, so let's break out the cheat code - a mag drill and an annular cutter.
Love these things, they go through steel like butter. Here's one of the rails drilled with the bolts test fit in the holes I plan to use.
Clamped in place so I can tack it:
Tacked, and lining up the front mount both by measurement as well as using an actual hitch.
Lather, rinse, repeat for the front mount.
And then some final test fitting after the clamps are off.
All good. Tomorrow morning before it gets warm I'll finish weld them, and then start on building parts for the tire carrier.
gprguy
Well-Known Member
Finish welded the hitch mounts.
Pretty happy with how that came out. Next up is the spare tire carrier/well/whatever.
My plan was to build a well that was big enough to put a 34" diameter tire in so I'd have the option of 245's if I want someday. Unfortunately that's not going to work out, here's the first attempt.
It's just clamped to the outside to get an idea of fitment and the tops have to be chopped off, but the rear of it is basically into the tires and it'll only get worse as the tires stuff.
So the next attempt I took 1" out of the middle, so it can only hold a 33" tire, or a 225 (about 32") with some wiggle room. This happens to match up with the existing crossmembers in the deck however, so it's going to be less work and stronger at the same time.
It's hard to tell with camera angles, but it's getting better. I am going to need to angle the rear part of the bar differently, cutting that last corner off a bit. But first I am going to dump the air out of the suspension to see worst case.
Back at it tomorrow.
Pretty happy with how that came out. Next up is the spare tire carrier/well/whatever.
My plan was to build a well that was big enough to put a 34" diameter tire in so I'd have the option of 245's if I want someday. Unfortunately that's not going to work out, here's the first attempt.
It's just clamped to the outside to get an idea of fitment and the tops have to be chopped off, but the rear of it is basically into the tires and it'll only get worse as the tires stuff.
So the next attempt I took 1" out of the middle, so it can only hold a 33" tire, or a 225 (about 32") with some wiggle room. This happens to match up with the existing crossmembers in the deck however, so it's going to be less work and stronger at the same time.
It's hard to tell with camera angles, but it's getting better. I am going to need to angle the rear part of the bar differently, cutting that last corner off a bit. But first I am going to dump the air out of the suspension to see worst case.
Back at it tomorrow.
gprguy
Well-Known Member
Here's the suspension dumped, full stuff. The piece of aluminum clamped in place represents what I'd like the piece to end up as far as tire clearance.
Something like this:
Some welding and grinding later and here we go:
Still needs the tops trimmed off but this is pretty close to where I want it.
Now I need to make a copy so I have two cradles, one per spare tire.
Something like this:
Some welding and grinding later and here we go:
Still needs the tops trimmed off but this is pretty close to where I want it.
Now I need to make a copy so I have two cradles, one per spare tire.
dieselscout80
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Looks good however, it will be a bear if you ever need to put tire chains on it.
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Or run a larger tire
gprguy
Well-Known Member
Keep in mind all of the photos in that last post were with the suspension dumped entirely, and there's still 1.5" of clearance. The truck would never be driven, let alone with chains, like that. Ride height is another 3-4" up and the suspension really only moves downwards with the 4 link (ok, technically it moves slightly forwards as well in an arc, but not an appreciable amount with the short amount of travel in this setup).
I can also raise the entire truck quite a bit further with the push of a button if I need some temporary extra clearance.
That said traction aids are something I have in mind, mainly for legal reasons with the passes out here. I don't foresee using them frequently so odds are I will carry a set of tire socks to satisfy the requirements. With my 3500 we went over the passes in heavy snow and ice several times and didn't feel the need to do anything more than put it in 4wd.
That ship has unfortunately sailed for many reasons. I was hoping to be able to accommodate 245's if I wanted in the future, but it's not going to happen. It's probably just as well since I have 4.10's.
gprguy
Well-Known Member
Started today by adding a couple more pieces to the flatbed, this will be the "back" of the tire cradle.
Then I duplicated the existing cradle I made yesterday.
Followed by making a big L piece that will form the back and bottom of the cradle.
Tomorrow once I trim the two cradles to height, I can start sticking these together and get them tacked on the flatbed. My plan is to put it all together, probably even finish weld it into the flatbed, and then cut out the part of the flatbed that needs to go away. Should help keep things square-ish.
Then I duplicated the existing cradle I made yesterday.
Followed by making a big L piece that will form the back and bottom of the cradle.
Tomorrow once I trim the two cradles to height, I can start sticking these together and get them tacked on the flatbed. My plan is to put it all together, probably even finish weld it into the flatbed, and then cut out the part of the flatbed that needs to go away. Should help keep things square-ish.
gprguy
Well-Known Member
Today was one of those satisfying days where everything comes together after days of building random parts and subassemblies.
First off today was trimming the cradles to the right height, and then welding the outer cradle to the center part.
That went right in place easily so it could be tacked to the main frame.
Next up was adding the inner cradle as well as some cross braces.
All tacked together.
At this point I decided to put the rear end back at more-or-less ride height. It's hard to get it perfect without the compressor and manifold hooked up and I haven't had time to get back to that. I also finish welded most of the cradle. Some joints will have to wait till the bed is off though.
Good enough for me. There's 2" of clearance at the closest point, and I will add a fender liner at some point made from 1/8" aluminum or something.
Deep breath.. Time to hack a big chunk out of the bed I just built.
That's just rough cut of course. I am pleased at how little things moved after taking that chunk out.
A little trimming of the sides and here's one spare sitting roughly in place.
I'm pretty pleased with how it's coming out. The measurements all look good for the camper as well. If I try to carry both spares with the Lance it may be a little tight on the inner spare, but I can always just carry one for now. Future camper should have tons of room for both.
Next up is building the mount that will hold the tires in place.
First off today was trimming the cradles to the right height, and then welding the outer cradle to the center part.
That went right in place easily so it could be tacked to the main frame.
Next up was adding the inner cradle as well as some cross braces.
All tacked together.
At this point I decided to put the rear end back at more-or-less ride height. It's hard to get it perfect without the compressor and manifold hooked up and I haven't had time to get back to that. I also finish welded most of the cradle. Some joints will have to wait till the bed is off though.
Good enough for me. There's 2" of clearance at the closest point, and I will add a fender liner at some point made from 1/8" aluminum or something.
Deep breath.. Time to hack a big chunk out of the bed I just built.
That's just rough cut of course. I am pleased at how little things moved after taking that chunk out.
A little trimming of the sides and here's one spare sitting roughly in place.
I'm pretty pleased with how it's coming out. The measurements all look good for the camper as well. If I try to carry both spares with the Lance it may be a little tight on the inner spare, but I can always just carry one for now. Future camper should have tons of room for both.
Next up is building the mount that will hold the tires in place.
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gprguy
Well-Known Member
So it will probably come as a surprise to no one that while tire mounting plates for Jeep lug patterns, or 8 on 6.5, etc are easy to find - but no one seems to make one for 10x225mm. 
No big deal, I just need to make one myself.
CNC Plasma cut 3/8" main plate, and then I added an additional 1/4" spacer as the lug studs have a shoulder that needs the extra thickness.
I cut out all 10 holes, but odds are I won't use all 10. The CNC plasma table I have access to needs some maintenance so the holes aren't perfect. I may add another stud or two but to be honest the 4 that are there are more than plenty.
Anyway, after that was built it was a matter of heaving both spares in place and bolting the plate to the back side.
Shot from the backside of the gap I need to fill with a piece of steel to mount the tire plate to the bed:
Part way through figuring out this new plan for the tires, I realized I now had a use for the black center caps I wasn't going to put on the actual wheels.
I'm kind of digging the black center cap and the silver wheel paint. Matches the truck nicely.
I cut the piece of steel (3x2" .250 wall box tube) but I will probably spend a while making sure everything is sitting exactly where I want before welding it in place.
Hoping I can get this tire carrier finished tomorrow so I can move on to the next part.
No big deal, I just need to make one myself. CNC Plasma cut 3/8" main plate, and then I added an additional 1/4" spacer as the lug studs have a shoulder that needs the extra thickness.
I cut out all 10 holes, but odds are I won't use all 10. The CNC plasma table I have access to needs some maintenance so the holes aren't perfect. I may add another stud or two but to be honest the 4 that are there are more than plenty.
Anyway, after that was built it was a matter of heaving both spares in place and bolting the plate to the back side.
Shot from the backside of the gap I need to fill with a piece of steel to mount the tire plate to the bed:
Part way through figuring out this new plan for the tires, I realized I now had a use for the black center caps I wasn't going to put on the actual wheels.
I'm kind of digging the black center cap and the silver wheel paint. Matches the truck nicely.
I cut the piece of steel (3x2" .250 wall box tube) but I will probably spend a while making sure everything is sitting exactly where I want before welding it in place.
Hoping I can get this tire carrier finished tomorrow so I can move on to the next part.
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Rockcrawlindude
a rock crawlin’ dude
Everything looks amazing. Great job. Keep up the good work. I worry the Trucks gonna be out of warranty before it’s out of the shop.
gprguy
Well-Known Member
Thanks - you and me both. Wish I had more time to dedicate to it. But I think I'm getting close to minimum viable product as they say..