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4500 Camper/Jeep Hauler Build
- Thread starter gprguy
- Start date
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- 4500 camper chassis cab jeep
gprguy
Well-Known Member
Thanks. I've seen some service and dump bodies along these lines, but they usually are more square just for ease of manufacturing.. I should have taken the hint. 
I've been busy working but not all of it is photo worthy. Things like measuring for wiring, measuring and ordering hydraulic hoses, etc. I finished up the air tank mount today. Started by cutting a piece of 3/16" plate with the CNC Plasma based on my cardboard design.
It bolts to two crossmembers under the truck which unfortunately aren't exactly the same height. So the rear one gets this piece of 2x2" tube sliced down and welded over the rectangular cutout in the plate.
I also decided in the end to stitch weld a couple pieces of angle to give a bit more stiffness - probably not really needed, but better safe than sorry.
Bolted in place. Only one hole drilled, the rest used unused weld nuts on these crossmembers.
And the tank bolted in place. I don't remember if I mentioned but it's a 12 gallon from Hornblasters. Biggest tank I could find that would fit down here.
It's higher than the exhaust or the DEF tank so I'm happy with the placement.
After all of that I took it back out so the bracket can be powder coated along with the bed when the time comes.
Next up was the mounts for the gas struts. The good news is they fit, I did my math right there.
The not great but not unexpected news is I undersized the struts - no big deal, it was an educated guess. So they aren't quite strong enough to hold them up - hence the cardboard tube assist. I ordered the next size up to swap in.
The unfortunate news is the top of the bike rack slightly clips the strut mount, so I am going to have to trim it. Sad since it was already powder coated, but so be it. It'll get re-coated along with the bed.
Plan for tomorrow is to add the weather stripping, finish the latches, and probably hack the corners off the bike rack. That'll set me up for doing the back wall.
I've been busy working but not all of it is photo worthy. Things like measuring for wiring, measuring and ordering hydraulic hoses, etc. I finished up the air tank mount today. Started by cutting a piece of 3/16" plate with the CNC Plasma based on my cardboard design.
It bolts to two crossmembers under the truck which unfortunately aren't exactly the same height. So the rear one gets this piece of 2x2" tube sliced down and welded over the rectangular cutout in the plate.
I also decided in the end to stitch weld a couple pieces of angle to give a bit more stiffness - probably not really needed, but better safe than sorry.
Bolted in place. Only one hole drilled, the rest used unused weld nuts on these crossmembers.
And the tank bolted in place. I don't remember if I mentioned but it's a 12 gallon from Hornblasters. Biggest tank I could find that would fit down here.
It's higher than the exhaust or the DEF tank so I'm happy with the placement.
After all of that I took it back out so the bracket can be powder coated along with the bed when the time comes.
Next up was the mounts for the gas struts. The good news is they fit, I did my math right there.
The not great but not unexpected news is I undersized the struts - no big deal, it was an educated guess. So they aren't quite strong enough to hold them up - hence the cardboard tube assist. I ordered the next size up to swap in.
The unfortunate news is the top of the bike rack slightly clips the strut mount, so I am going to have to trim it. Sad since it was already powder coated, but so be it. It'll get re-coated along with the bed.
Plan for tomorrow is to add the weather stripping, finish the latches, and probably hack the corners off the bike rack. That'll set me up for doing the back wall.
gprguy
Well-Known Member
Since I am done with the fabrication around the doors, I swapped in the new control panel housing that I 3D printed out of PETG for some more heat tolerance. I also printed it on a textured sheet this time and I really like the new look.
Then I installed the weather stripping. Truth be told this stuff is probably slightly too thick, but the next thinner size was too thin. I'm hoping it squishes down over time.
Installed the rest of the latch parts - I may try to tighten them down a little more after they sit for the night closed up, to see if the weather stripping compresses any. But here's the door, latched in place for the first time. Also - argh fingerprints!
Next up is the rear wall of the cabinet, and I started laying out lines for the rivets towards the end of the day.
My goal is to get the rear wall fully installed by the end of the week. At that point other than some loose wires that need tying up/protecting, it'll be drivable again for the first time since the spring.
Then I installed the weather stripping. Truth be told this stuff is probably slightly too thick, but the next thinner size was too thin. I'm hoping it squishes down over time.
Installed the rest of the latch parts - I may try to tighten them down a little more after they sit for the night closed up, to see if the weather stripping compresses any. But here's the door, latched in place for the first time. Also - argh fingerprints!
Next up is the rear wall of the cabinet, and I started laying out lines for the rivets towards the end of the day.
My goal is to get the rear wall fully installed by the end of the week. At that point other than some loose wires that need tying up/protecting, it'll be drivable again for the first time since the spring.
oledirteh
Well-Known Member
amazing man. just amazing. your attention to detail and just getting it done is just mind-blowing to me. i wish i had someone local to me with skills like this just so i can hang out and learn more than what i know now.
I really like that enclosed section that you are building. Especially the pass through nature.
I end up with a lot of things more or less the size of a full size suite case - that sit flat ~ 12 inches tall.
Looked at service bodies, but they are kind of clunky looking and most are not able to deal with items like that.
I end up with a lot of things more or less the size of a full size suite case - that sit flat ~ 12 inches tall.
Looked at service bodies, but they are kind of clunky looking and most are not able to deal with items like that.
Bigboom338
Active Member
Hats off to you on your build. Amazing.
I hope you remember well how your 3500 handled your 1062, you are not going to believe the difference when you get it on your new truck. I just got back from a 2800 mile 2 week trip through the hills of Kentucky, North Carolina and Tennessee. The way these trucks handle TC's compared to a pickup is unbelievable.
After you add all of your mods, your first trip out with the camper on, well I can't wait to hear your report about that.
I hope our paths cross some day.
I was at a Lance gathering recently and was talking about your build.
I hope you remember well how your 3500 handled your 1062, you are not going to believe the difference when you get it on your new truck. I just got back from a 2800 mile 2 week trip through the hills of Kentucky, North Carolina and Tennessee. The way these trucks handle TC's compared to a pickup is unbelievable.
After you add all of your mods, your first trip out with the camper on, well I can't wait to hear your report about that.
I hope our paths cross some day.
I was at a Lance gathering recently and was talking about your build.
gprguy
Well-Known Member
Thanks very much.
I am really looking forward to it. To say we are going a little stir crazy would be an understatement, we used to average 12-15k miles a year camping and now it's been a year and a half of no camping at all. However, we are getting close, and have a plan for at least one trip before year end that I think is entirely achievable. After that it'll be back in the shop for a few more months to finish up odds and ends and under-bed storage.
We are looking forward to hitting some gatherings/rallies too. We had a lot of fun at Overland expo mountain west in 2022 - although it looks like they no longer welcome bigger rigs now. Quartzite has been on the list of course.
Quick progress update - holes, lots of holes being drilled.
After that, I fitted the 3 trim pieces on the driver's side.
Tomorrow is the passenger side and then the flat strip across the back. I plan to have the cabinet enclosed by the end of the week.
The weatherstripping is compressing down as hoped for too - glad to see that. The new struts show up Thursday and hopefully those will be the right size.
I am really looking forward to it. To say we are going a little stir crazy would be an understatement, we used to average 12-15k miles a year camping and now it's been a year and a half of no camping at all. However, we are getting close, and have a plan for at least one trip before year end that I think is entirely achievable. After that it'll be back in the shop for a few more months to finish up odds and ends and under-bed storage.
We are looking forward to hitting some gatherings/rallies too. We had a lot of fun at Overland expo mountain west in 2022 - although it looks like they no longer welcome bigger rigs now. Quartzite has been on the list of course.
Quick progress update - holes, lots of holes being drilled.
After that, I fitted the 3 trim pieces on the driver's side.
Tomorrow is the passenger side and then the flat strip across the back. I plan to have the cabinet enclosed by the end of the week.
The weatherstripping is compressing down as hoped for too - glad to see that. The new struts show up Thursday and hopefully those will be the right size.
Eatonpcat
Well-Known Member
Getting close Brother...Exceptional Fab Work!!
gprguy
Well-Known Member
Another milestone today - I'm done with trim work on the cabinet.
I still have to drill out a lot of the punched holes tomorrow, but it should be ready to glue and rivet on Friday.
I still have to drill out a lot of the punched holes tomorrow, but it should be ready to glue and rivet on Friday.
gprguy
Well-Known Member
Holy crap was that a lot of rivets.
Need to clean up all the excess sealant tomorrow, and then it may be on to wiring for the cabinet.
Need to clean up all the excess sealant tomorrow, and then it may be on to wiring for the cabinet.
gprguy
Well-Known Member
It took several attempts to find the right gas shock sizing - starting at 40lbs, then 50, 60 - turns out 90 is the right size given all of the leverage. So we have a gull wing door Ram.
Going to start on the wiring between the engine bay and the cabinet tomorrow.
Going to start on the wiring between the engine bay and the cabinet tomorrow.
gprguy
Well-Known Member
Wiring is moving along, but I didn't take any photos yet - but the wiring is all run under the truck, still putting ends and connectors on it though. Was doing it in a bit of a hurry to get the truck drivable to help with a side project that's taking priority for the first half of this week.
However that means the truck is back on the road to help with that project - for the first time since May I think.
Drove great, no rattles to speak of. The plan is to get the wiring under the truck finished so it's more weatherproof than it is now, then finish the bed, and then finish the wiring inside the cabinet and the plumbing while the bed is off at powder coat. And somewhere in there the poor truck will get a bath.
At least that's the current plan.
However that means the truck is back on the road to help with that project - for the first time since May I think.
Drove great, no rattles to speak of. The plan is to get the wiring under the truck finished so it's more weatherproof than it is now, then finish the bed, and then finish the wiring inside the cabinet and the plumbing while the bed is off at powder coat. And somewhere in there the poor truck will get a bath.
At least that's the current plan.
Great White North Eh
Squish Cat - And So
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Did it need sunglasses when you pulled her out? 
gprguy
Well-Known Member
Thankfully (?) the coating of dust diffused the reflection somewhat.Did it need sunglasses when you pulled her out?
gprguy
Well-Known Member
Side project is done - full steam ahead on the truck again. I've been working on the wiring the last couple of days, plotting out where the two 12 pin Deutsch DTM bulkhead connectors will go.
Those will be mostly for the air system and sensors, plus a couple of other small wires. Alongside that there are two 4awg wires for the Orion-XS DC-DC charger. There's a weatherproof Anderson SB120 connector under the box so the box could be disconnected if it had to be.
The short term plan is to get the chassis side of those Deutsch connectors wired up along with the Orion charger. That'll also require me to install the fuse panel for the cabinet, although I'll just do the minimum for now. Once that's all done, back to the bed so I can get it off to powder coat.
Those will be mostly for the air system and sensors, plus a couple of other small wires. Alongside that there are two 4awg wires for the Orion-XS DC-DC charger. There's a weatherproof Anderson SB120 connector under the box so the box could be disconnected if it had to be.
The short term plan is to get the chassis side of those Deutsch connectors wired up along with the Orion charger. That'll also require me to install the fuse panel for the cabinet, although I'll just do the minimum for now. Once that's all done, back to the bed so I can get it off to powder coat.
gprguy
Well-Known Member
More wiring. Finished up the connections underneath the box so that gets rid of all of the loose wiring, everything is weatherproof now. Glad that job is done, tired of lying under the truck.
All of the wiring for the Deutsch connectors on the top side still needs doing, but the underside is good to go.
Next up was getting the DC and AC load centers mounted on the removable panel I made a while back.
I then got it installed because I wanted to finish wiring the Orion XS DC-DC charger.
The good news is the charger works great. I'm really impressed with the Orion XS compared to the older Orion Tr we have in our camper.
The bad news is I may take that all back out again because I forgot to add rivnuts to mount the 3 relays for the air control system. I may get into that tomorrow, and then I need to hook up a couple things from under the dash to the harness I ran along the frame - I need keyed power as well as a parking brake ground signal off of the VSIM run to the cabinet.
All of the wiring for the Deutsch connectors on the top side still needs doing, but the underside is good to go.
Next up was getting the DC and AC load centers mounted on the removable panel I made a while back.
I then got it installed because I wanted to finish wiring the Orion XS DC-DC charger.
The good news is the charger works great. I'm really impressed with the Orion XS compared to the older Orion Tr we have in our camper.
The bad news is I may take that all back out again because I forgot to add rivnuts to mount the 3 relays for the air control system. I may get into that tomorrow, and then I need to hook up a couple things from under the dash to the harness I ran along the frame - I need keyed power as well as a parking brake ground signal off of the VSIM run to the cabinet.
gprguy
Well-Known Member
Wiring is done, for now - there's a lot more to do, but it's hooking things up in the box which I'll do as I have spare time.
First off, hooked up the AC out from the multiplus to the AC load center.
Also I found a home for the 3 relays for the air system - hidden under the edge of the tray, you can see the 3 brackets in the lower left. Mounted the MPPT too next to the Orion.
And finally, I hooked up the wiring to under the dash and VSIM. No pictures because it's not interesting. I'll just say that whomever decided to put D2433A and D2621A where they are under the dash - very effective torture devices you engineered there, sir/ma'am. My hands should stop bleeding in a few days..
That let me get the hydraulics wired up which was pretty cool.
Blinky lights and all. I don't have the hoses installed (though I do have them) so I can't fill and test the system yet.
Back to welding on the bed tomorrow to get that thing finished.
First off, hooked up the AC out from the multiplus to the AC load center.
Also I found a home for the 3 relays for the air system - hidden under the edge of the tray, you can see the 3 brackets in the lower left. Mounted the MPPT too next to the Orion.
And finally, I hooked up the wiring to under the dash and VSIM. No pictures because it's not interesting. I'll just say that whomever decided to put D2433A and D2621A where they are under the dash - very effective torture devices you engineered there, sir/ma'am. My hands should stop bleeding in a few days..
That let me get the hydraulics wired up which was pretty cool.
Blinky lights and all. I don't have the hoses installed (though I do have them) so I can't fill and test the system yet.
Back to welding on the bed tomorrow to get that thing finished.
Great White North Eh
Squish Cat - And So
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Get some lines installed! We want to see the big girl dance.
gprguy
Well-Known Member
You and me both, but I need to get this bed done and off to powder coating if I want any chance of camping this year. I'll get those hooked up while they have the bed.Get some lines installed! We want to see the big girl dance.
