1 Bored Clerk's Garage Built Camper

Ooh! Do you have a link? I had to modify my filler tubes anyway for the flatbed. I have the most updated overfill valve sitting ony bench to install but to be honest, I don't have a lot of faith in it since this will be my third valve design.

 

Links to what you'll need are at the bottom of this article.

https://www.fillernecksupply.com/bl...-and-overflow-at-the-gas-station-pump-nozzle/

 

Thanks! I'm going to install the "new and improved" version I have on my workbench for now. And if it falls, I can easily add this setup inline without removing the camper or dropping the tank.

 

Patch panel roughed in.

Now I wait... Wait for the epoxy to cure then sand it all down. Then the process to glass and fair it all in.

I also need to make a gas filler mount on the front of the camper. That will be like all of the other mounts on the camper: marine grade 1/2" plywood with ss furniture nuts embedded in the back and epoxy sealed. Glass that to the front of the camper and I'm good to go.

 

I just placed my order for the backflow valve and tubing that Wild Crow linked. My filler tubing is starting to crack and I think this new setup will be cleaner. Plus, I just don't want to deal with the mega hassle to replace the in tank valve. Also, it'll be easy to service the new valve should that become necessary.

 

First layer of glass on the outside. I sanded down the epoxy used to fix the panel in place then wiped with acetone then epoxy, glass and more epoxy. A bit of squeegee action and here's where I am. I don't have enough glass to do the second layer right now so I'll have to go buy more. No biggie because...


With all of the folds in this glass fiber sheet I had, I missed that a portion of it had been affected by a drop of epoxy in the past (probably). So it is a bubble that can't be fixed. I'll wait until this cures then sand that out, epoxy fill the void and glass over it again. No big deal...it happens. Especially when you're as scattered and sloppy as I am sometimes!

 

A little mid afternoon glassing
Rough sand layer one, clean with acetone and epoxy layer two in place. This will cure then I'll move to the interior tomorrow. I just don't feel like doing more than 15 minutes of work at a time, I guess.


I also received my order for the backflow valve system. There is a small, easily replaceable backflow valve, some reducers and a couple of pieces of tubing. I didn't know exactly how I wanted to arrange this on the truck so I just ordered enough stuff to do it several ways.

Ill start designing my subframe today in CAD too. That needs to get done ASAP because the lead times on that and powdercoat will be on the order of weeks.

 

Took a little time just now to work on the camper. Rough sanded the exterior glass, wiped with acetone then added a layer of fairing compound. I'll sand this down tomorrow after it has cured.

I also sanded the first epoxy bead sealing the patch panel on the interior. Then I wiped it with acetone and hit it with another layer of thickened epoxy and used a spreader to fair out the difference between the patch and the wall. I'll sand that smooth tomorrow and add both layers of glass at the same time for efficiency's sake.

Then I'll brace for rain for the next 7+ days. Which is fine. I'll get my subframe designed and out for cut/bend during that time.

 

Sanded down the exterior and decided to go with another coat of fairing compound. It may take several rounds to get it where I want it. No biggie as long as we don't get rain.




I also got two layers of glass over the interior patch area. I sanded any epoxy runs and glass edges down already too. I'm not going to do much here as it will be covered with padded panels. I'll give the interior a good cleaning then prime and paint. I'll do that the same time I paint the exterior and use the same seafoam paint color.

I'm nearly done with my subframe design. I just want to make sure I check EVERYTHING a million times before I send it all out for cut and bend. With prices being what they are right now, this isn't going to be cheap so I'd like to nail it the first time around. I imagine when I send all these parts out for cut/bend, I'll be MUCH quicker about finishing this patch and getting my fuel filler mount on the camper. Oh, a new fuel filler clamp/mount is out for quote too.

 

I got all of my files out for cut/bend for my sub frame yesterday. Got the quote back and gave it the green light. 2.5 weeks or so lead time.


This doesn't show everything but it's close. It will mostly be aluminum except for the angle steel crossbars and four brackets. The parts that bolt directly to the frame will be steel. Everything from there up is aluminum. Not unlike the flatbed this replaces.

I still need to buy some lengths of angle steel and aluminum for brackets that I can easily cut to length in the garage. No need for custom parts or their cost. And there will be a decent number of fasteners needed as this is most entirely a bolt together system. I went that route for speed and flexibility during initial fitup.

 

gonna look good

 

Yeah, should be nice. Assuming it all fits together and I got my measurements close enough!

I'm considering getting a couple of dimple dies and putting some dimples on the cross braces. Not really gonna lose much weight but it would stiffen the cross braces a bit. Mostly, I've been wanting a reason to get some dies for several years and I'm trying to talk myself into it for this project.

 

Ouch, very punny.

 

Not a lot going on with the camper. I could be making headway on lots of areas but I'm not.

I did get this party started...


I got a new fuel filler mount machined. And I started making the mounting lug that will epoxy and glass to the front of the camper. I should be able to wrap this up this week. Once that's on the camper, I can do any finish sanding necessary then prime and paint. I need to get on it so I'm ready when my subframe is ready.

 

More slow work on the fuel filler mount
Get the placement and orientation where I want it and drill some pilot holes. Drill those out, clean out the plastic honeycomb then fill with epoxy. This will give me a good plug to drill into, dill with epoxy then screw in stainless steel screws.


Then lay two layers of fiberglass, epoxy and screw the mount base to the camper and epoxy fill the screw heads. The epoxy is such a mess because I put a fresh layer of laminating epoxy on before the thickened epoxy so the thick stuff only had the way more slippery laminating epoxy to hold onto...which it doesn't very well. This general method is the same way I attached all of the L Track to the side, top and back of the camper.


Oh, I also sanded the last application of fairing compound. Once the fuel filler mount is finished, I can paint this.


Put a good epoxy fillet around the base then placed a strip of fiberglass over the top of the fuel filler mount in each direction. It started to rain so I sealed it up to cure. When it's dry again on Friday, I'll sand this smooth, apply an epoxy coat and another layer or two of glass over the whole mount. Them a little sanding, fairing compound and more sanding. THEN it'll be ready for paint. Hoping to get primer on this on Sunday. That reminds me, I need to go buy primer and paint. Hopefully it's in stock!

My subframe parts should be ready to pick up tomorrow. Fingers crossed they're done as it seems to be a good day to take a break from work to pick them up. In reality, picking them up anytime before this weekend would be fine.

 

Make sure you design/build in a way for flex between frame and subframe.

 

The subframe will flex as needed like the flatbed used to. The camper will be isolated from that with the body mounts as before. The only thing I need to be careful of is making the subframe too stiff. It's all bolt together and doesn't stray too much from the general construction method of the flatbed. But there are some places that I was thinking if adding bracing that may be better left to move a little. Over constraining is risky.

 

Have you ever used West Systems Six-10 thickened epoxy? If you are not familiar with it, it comes in a caulk tube, and is thickened, ready to go. It mixes in the nozzle.

Assuming you add a thickening agent to your epoxy, the Six-10, while a little more expensive, would be easier on small jobs.

I have used it for a couple of projects, and really like the convenience.

 

I use that stuff often. It is awesome! I might have used it here but I had some leftover epoxy mixed so it made sense to use that with a thickening agent rather than throwing it away.

 

Picked up all of my subframe parts this morning. Got something I didn't expect so I had to check my paperwork. I did a typo...instead of .125" I typed .25" on my fender tops. So those are now ridiculously over done for what they are. They are aluminum so that's good but still. I'll mock those up into place and see if it's good or just too much then decide what to do if anything.