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4500 Camper/Jeep Hauler Build

Weather's about to change here and go from nice to fall starting tomorrow, so we did some leak testing on the cabinet. Only a few small leaks, some of which I've already fixed, one or two that need further investigation, and some others that I kind of expected. I need to build some baffles for the front vents, if water sheets down there it tends to get a little inside since the louvers don't overlap. Also the DEF hoses need some sealant added to the grommets. After that, gave the truck a wash for the first time in close to a year.

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The amount of filth that came off the truck was impressive. After that it was back to working on the bed - I finished up hopefully the last of the welding on the underside of the steel frame, other than some brackets I need to add for the future storage boxes. I've also started attaching the aluminum top to the steel bottom using these brackets I picked up.

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There will be additional, stronger things holding the deck down as well - but these will help locate it and keep it snug when there isn't a load on it.

I've also started reworking the front fuel filler - I decided that if I made the front one more rectangular instead of an angle down to the deck I'd have room to hide both the 7 way and the Lance 6 pin connectors on the backside. Something like this, but of course spaced a bit better.

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On the front side I'll leave the angled bit for triangulation, and just square it off above.

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Once I have the filler at least tacked together it'll be back on those little brackets, and then more on the aluminum deck.
 
It's been a week of tedious little brackets along with life getting in the way. The good news is the brackets are essentially done - I'm going to make one more today, and that will finish up that project.

I'm also pretty much done with making the front fuel filler housing bigger. Not my finest work but it's good enough. It'll end up skinned in aluminum just like the rear filler, just rectangular instead of triangular.

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Once I finish up that last bracket and a side project for my wife it'll be on to filling in the center of the framework that I couldn't reach when it was on the truck, and building "picture frames" around the 5th wheel rails.
 
Side project done - back to the bed. I've spent the last two days cutting, fitting and welding. It's getting there. First off, added another tie down bracket inside the front fuel filler since it's kind of just out there.

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The center section between the hitch rails is pretty much done and welded.

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And the front and rear center sections are partially done.

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Moving along..
 
The aluminum framing is done and welded (mostly, going to likely mig some of the vertical joints just because).

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Next up is trimming around the 5th wheel rails, and then it will either be starting the decking or sheeting around the fuel fillers - I haven't decided what order I want to do that in.

Meanwhile, it was a nice day yesterday and I thought it was about time to weigh the truck again. Much to my surprise I hadn't weighed it since July 2023, and at that time it weighed 9,250 with about 45 gallons of fuel and zero humans in it. At the time it had the kelderman suspension (no control system) and the bumper pull hitch.. And that's about it.

Since then, a non exhaustive list of what's been added: The kelderman control system (other than the tank), the hydraulic legs and control system, the midship fuel tank, the backpack cabinet with the slide in it, the big battery, inverter and all of the wiring and such. The truck now with again about 45 gallons of fuel in it (divided between the tanks) and no humans: 10,200. I think there will be a good chance of being at about 11k with the bed. It'll be a bit more in final trim with two spare tires, full tanks, and the future under bed storage boxes full of junk - but I'm happy with where this is heading at this point.
 
Been busy at work and working on the truck. Also I totally haven't gotten distracted by getting a 3D printer.... Anyway.

The trim around the 5th wheel slots has been tedious but is finally done. A couple in progress shots, including a deck board clamped in place to show how everything ends up flat in the end.

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And after some welding here it is 99% done. I still have to touch up some of the corners with the TIG once I move my argon bottle back over from the MIG.

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Once I get the welders swapped back around and finish those touch ups, the next task will be the 3 rows of L track. Then, believe it or not, it will be time to deck it. Getting there, slowly...
 
L track - there are 3 rows of L track (airline track) that go across the bed, flush with the deck boards. This will be useful for tying things down under the camper wings as well as for mounting camper guides and using for general tie downs when the camper isn't on the truck. The L track is from Mac's and is a square, blank profile (no holes). So all of the holes needed to be drilled through the track as well as a 5/16" aluminum bar spacer to raise them up and be level with the deck. My drill press is kind of in a corner and moving it would be a pain to be able to work on 8' long pieces, so I made a temporary drill press from the mag drill.

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That also let me countersink the heads using the same jig/back stop, which turned out much less blurry in real life than in this photo.

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Came out great, and it's just proud of the sample bit of deck board seen in the second photo. That's expected, I need to slot the bottom side of the spacers about 1/16" to account for the stainless rivnuts that are installed.

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I need to finish up a few brackets on the steel side of the bed while I can still reach through the bed, and then it will be deck board time.
 
gprguy said:
L track - there are 3 rows of L track (airline track) that go across the bed, flush with the deck boards. This will be useful for tying things down under the camper wings as well as for mounting camper guides and using for general tie downs when the camper isn't on the truck. The L track is from Mac's and is a square, blank profile (no holes). So all of the holes needed to be drilled through the track as well as a 5/16" aluminum bar spacer to raise them up and be level with the deck. My drill press is kind of in a corner and moving it would be a pain to be able to work on 8' long pieces, so I made a temporary drill press from the mag drill.

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That also let me countersink the heads using the same jig/back stop, which turned out much less blurry in real life than in this photo.

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Came out great, and it's just proud of the sample bit of deck board seen in the second photo. That's expected, I need to slot the bottom side of the spacers about 1/16" to account for the stainless rivnuts that are installed.

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I need to finish up a few brackets on the steel side of the bed while I can still reach through the bed, and then it will be deck board time.
Click to expand...

Good luck with the rivnuts. Some of my customers use them in van walls and there are nearly always spinners. Usually I find out when trying to attach something to them - have to undo everything and drill them out.
 
HarryN said:
Good luck with the rivnuts. Some of my customers use them in van walls and there are nearly always spinners. Usually I find out when trying to attach something to them - have to undo everything and drill them out.
Click to expand...
I tend to use them in thicker metal and have had great luck. The cabinet is full of them.
 
Starting to get somewhere now. Pretty cool to see it coming together like I had it in my head. I started with the hardest boards to fit, the "rear center" section. This has the most to trim and fit around.

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Here's where I finished off for the evening - that section is done from L track to L track. None of them are welded down yet, I plan on fitting them all before welding. They're going to have be welded/installed in a specific order to be able to weld all the tongue and groove sections correctly.

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Will probably knock out the rear section next since it's simple, and then keep moving forward.
 
Didn't have time to post these last night. I need to do some final trimming, and I think welding them down will be next. I was starting to plot out where the camper tie downs will go, but I think I want the boards fixed securely in place before drilling 4.5" holes..

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And here's the point of it all.. A totally flat bed with the L track and fifth wheel rails at the same level as the deck. Took a lot of measuring but it came out just as hoped.

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So most likely weld down the boards next and then start cutting holes for the camper tie downs and bracing them to the steel portion of the frame.
 
Been welding the deck down the last 3 days. It's surprisingly slow going, things keep trying to move around since it's aluminum. I'm down to the last 3 boards and unfortunately ran out of argon again. Need to get the bottle filled tomorrow and finish it up. No new pics because it looks exactly the same minus clamps..
 
Argon refilled, and deck is done being welded - all except for the very front board, which needs some more work up there before it gets glued in place for good.

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I need to get a few misc parts ready for powder coat, and then it'll be down to the last two bits for the bed - the front stop and the tie downs. I am hopeful it will be ready for powder sometime next week. Fingers crossed..
 
Looks like the powder coat may be an issue - the place I was going to go with can't fit it in their oven. Not sure what that will do to the schedule, TBD.. Either way, I finished getting the misc parts ready. Had to angle off the top of the bike rack, that hurt to cut a part that was already coated.

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I capped those off at the angle, and that's done. I also did some further test fitting with the spares and some finish work on the tire mount.

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Tomorrow it's either starting the tie down rings or the front lip - probably the tie down rings. I'm still trying to get the bed ready for powder by next week even though I doubt that will be happening.
 
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Powder Coating Group Overview - THOMARIOS

Powder coating is an advanced environmentally friendly method of applying a decorative and protective finish to a wide array of metal products. Powder coating is a dry coating system where an item is sprayed with electrically charged powder consisting of finely ground particles of pigment and...
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Too bad you are so far away...I used to work here and they could handle the larger pieces.
 
Tie down rings it is. I spent a good while measuring the camper and bed to try to get these in just the right places.

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No turning back now.

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After some minor trimming all of the tie downs fit nicely.

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They are stainless 6,000 lb swivel rings from Mac's. More than enough. I picked up some steel for the backing brackets and will work on that tomorrow.

Powder coat plan is coming together, but I likely won't have it back till mid December given the holiday and all.
 
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