1 Bored Clerk's Garage Built Camper

That awning looks pretty stout. What brand is it?

 

This is the Alu-Cab Shadow awning. It feels pretty stout. I really like that it doesn't require any poles or guy lines unless it's pretty windy. It does have deployable legs and guy lines though, should you need them. And I like the idea of the 270 degree swing. Not sure I need that feature but we'll find out!

 

Nice, Thank you for information.

 

I still think you should build a matching roof box to eliminate any whistling. It would of course need to be shorter in height if you ditch the flat bed and lower the camper box. It has turned out nice- hope you get a lot of use out of it.

 

Yeah, we'll see how it goes. It's all pretty quiet on the road now. There may be quite a few updates done next year but I'm just shooting to enjoy it this winter and really consider what I need or don't need.

 

Not a ton going on this week. Just a few updates:

1 - I just realized that there is essentially no way I'm going to have my awning installed by the time I leave for my Thanksgiving trip to Death Valley. Powder coat takes 10 business days...not gonna make it. If I get the steel parts all done and ready to go this weekend, I'll see if the powder coat shop I use can expedite but I'm not holding my breath. Not really concerned either way, honestly.

2 - Just ordered the last bits for my brake upgrade. I bought 5th gen 4 Runner front brake lines. Not the whole thing, just the small S shaped steel hard lines that go from the caliper to the knuckle. I know people have bent their factory Tacoma line to work but I didn't want to find out i didn't like that solution once I was already in there. I can't guarantee the 4 Runner lines work, I'm operating based on Toyota wanting parts commonality wherever possible (same brake fittings and brackets).

3 - I finally got my hands on a few leaf spring anti friction pads that actually look like they'll work. Most of the spring pads that I could find had large mounting pins for full size truck springs. The Tacoma uses a smaller pin diameter. I ordered a set that said they work for a tacoma...and they were clearly for a full size. But these new onesay just work to end the tyranny of the squeak!


The pad on the bottom is the one that looks like it'll work. I have All Pro Expo rear leaves but they have the same (or near enough to the same) diameter holes as the standard springs on my dad's 2004 Tacoma.

Two main goals for this weekend are getting my usb ports installed and wired up and getting that spring pad installed. If I get through that, I'll jump on the brakes...then the awning.

 

First weekend project "done". New spring pads on the main leafs of my spring pack at the back.


Jack the truck up just enough to mostly un-weight the pack you're working on


Use a big straight slot screwdriver or small pry bar to start opening up the spring gap


Then move to a big fat pry bar to hold the gap open far enough to remove the old pad (if you still have one) and drop in the new one


Spend the next few minutes using a Dremel and a file to reduce the pin diameter because finding one exactly the right size was seemingly not possible


Slide the spring pad in place and reverse the order of operations with the pry bars


And there you are!

I took it for a test drive and it was still creaking and squeaking...though it seemed maybe a little less...


So I pulled the rear most spring pad from the passenger side leaf spring since it was doing very little. Replaced it with a new one same as the other side. Took it for a test drive and still creaking and squeaking. So I went back the the issue I had with my first set of All Pro Expo springs: the military wrap on the front of the spring pack around the front bushing. On that original pack, the wrap was slightly too large and was sitting in the frame and creaking. So, I sprayed some Fluid Film all up in and around the front bushing between the frame and top of the military wrap. Took it for another test drive. MUCH less creaking but there was still some. Conclusion: It's probably time to take these packs completely apart and clean, paint and replace all spring pads and bushings. Or maybe get a new spring pack. I've been thinking I need slightly heavier springs back there anyway. So, I might get a custom pack made next year that can carry a little more weight. Until I get the camper setup all dialed in and the weight is not likely to change, I'll be spraying the hell out of my current packs with fluid film to keep them as quiet as possible with the least amount of effort.

 

Second project well under way.


Got the USB ports wired (on this end) and the enclosure velcroed in place. I know industrial adhesive backed Velcro may seem...cheesy but I'm hoping it gets the job done because, honestly, I just didn't feel like putting more work into it. I can always go back and re-do the mounting in the future if I need to.


Mounted the RAM wireless phone charger. I love these things! I used some very sticky tape to cover the status LED because it's too bright to sleep with it on. I also used VHB tape to mount the on/off switch directly to the body of the charger. It happened to fit perfectly all the way around. I'll be able to tell if it's on or off based on the charge status of the phone.


And there it is. I can mount two more things on the two balls above this but for now this is all I need. Now I'm breaking for lunch then I'll came back and wire these ports to my kitchen box fuse block...if it's not raining too much. If it is, I'll work on the awning mount.

 

I admire your craftsmanship. Everything you do is purpose built and has a professional feel to it (at least from my POV)

 

Ever tried Dual-Loc in lieu of Velcro?

 

Thanks!

 

I have at work but not for any personal projects. I just happened to have Velcro on hand.

 

Figured! For most stuff I like dual loc because you're not constantly pulling on it to move things.

 

Project two is done!


USB ports wired into the fuse block


Ports work great! And my black tape is very sticky and also very translucent.

 

The plan was to swap the brakes today but it was so cold and there was a wisp of wind. I figured by the time it warmed up enough, I may not have enough hours to do the job. So I switched over to awning/roof rack work. Quick clean of the garage to blow out all the sawdust so I don't burn down the garage then I was ready!


I measured from the driver's outside wall of the camper over to one of the brackets I bolted in place on the roof to get the placement for my first rack upright. Then weld...then back up on the roof to mark the location of the other bracket. Then back into the garage to weld it up.


One ready to go! Two more to follow.


Here are two of the cross ars mounted to the camper. I was hungry so I drove this to lunch. Up the freeway and back on back roads. I didn't notice any whistling or even any increased wind noise so that's nice.



Here's a view of the roof mounts. I'll be doing this same thing on the driver's side wall at some point in the future (winter) for surfboards.


Here's a close-up of a tack weld that went all kinds of wrong. But it looks like a little tiny skull so it stays.


Three cross bars ready to go.



In between welding, I started cutting off steel I don't need from my awning mount. Why I didn't get this made out of aluminum is beyond me.
I may even just finish all the fit up then transfer all the changes into my CAD file then get a ready to go version made up from aluminum before I finish mount everything.


Here's where the awning mount goes. You can see how much crossbar I'll have to cut off. I'll cut them to length then weld on some angle steel so they can bolt to the awning mount.


And that brings the day, and the weekend, to a close. Not a bad way to finish it off.

 

Made the call today...literally. I called the brake and alignment joint I used to align my truck using SPC upper arms and some crazy verbal instructions in order to get my 255/85s to fit with no/minimal rubbing. They are going to install my 4Runner brakes next Tuesday morning. It was taking too long for me to do it and it would be a total pain at my house now that the truck doesn't fit in the garage. That's a bigger deal than I ever thought it would be.

 

What caster are you running? I think I'm on +2 atm. I may kick it out to the maximum the SPCs allow now that I have a HC bumper.

 

I can't remember at this point. I have enough of everything to drive pretty well and not wear tires strangely. if I come across the paperwork, I'll let you know.

I'd like to get a full bumper at some point. Relentless used to have all of their bumpers available in aluminum. That's what I'd go for...basic bumper in aluminum.

 

I went through coastal since you save a bunch with it being a weld-it-yourself kit. Now my welds are the best, but that's what a grinder's for! Aluminum would be another beast altogether. I'm not super great when it comes to TIG. They do offer them in aluminum for an upcharge.
https://www.coastaloffroad.com/product-page/2nd-gen-tacoma-high-clearance-plate-bumper/

 

Interesting. I didn't realize this was a thing. I can add a spool gun to my welder but I think I'd just buy a ready made bumper. Not sure I want to turn that into another project!