My Camper Build

[JandDGreens]

So when my sons' XJ took a turn for the worst, I decided to take advantage of it. We bought another XJ for him and use it the other to modify mine. (axles under mine) I decided to make a small camper out of it. This is a rough draft of things to come.

[JandDGreens]

Pictures, this tongue is temporary.

[JandDGreens]

More pics. Quarter panel repair

[JandDGreens]

Gutting the floor so it can be tub-ed

[JandDGreens]

This is where I am at with this I'll be working on it though the winter. I hope to have it far enough to use it this summer.

[dieseldoc]

Nice keep plugging along.

Get in touch with evan (synergyxj) he has a large solar pannel on his xj
I bet it would be grwat to power things in your camper!

[94ToyBear]

Dang it now i want one !
Keep it up !

[78bj40]

Looks great, can't wait to see the finished product

[DW Tim]

We never did talk about you build. Looking good bud

[Java]

Cool project! I like your garage too. :thumb:

[JandDGreens]

Here is a link to the Co. that I plan on getting my hitch from
Link;https://locknroll.com/shop-now/trailer-side/pn-504-v-shaped-frame-trailer-tongue/

One thing nice about this project is dismantling the XJ. If I end up doing more than one I'll become an expert at taking things part (ie; dash to get to the heater core). Also should get better at building them. But we will have to see how this one turns out.

[xaza]

I like the lock N roll, it is what I put on my trailer. I found out they have pivoting pintle and hook designs which look sweet too, the way to go for a heavy trailer.
http://www.wallaceforge.com/pintle-hooks/swivel-mounted-pintle-hooks.aspx

[JandDGreens]

I like this hitch because I think it will eliminate twisting the trailer frame which would put to much stress on the bumper mounts and the XJ frame. I don't intend to take it on radicle trails but I am building this thing to take a beating.

[JandDGreens]

So I finally got rid of the front of this thing. Now I will be shortening the cab to the length I want it to be.

[88Toy]

Hard to tell from the site pics, does this hitch allow twisting between tow(er) and tow(ee)?

[Hypoid]

I found this in the gallery: https://locknroll.com/gallery/gallery-category/

https://locknroll.com/wp-content/uploads/2012/03/New-LNR-Animation-273-x-205.gif

[JandDGreens]

If you go to their site, they have video of rigs wheeling with trailers using this hitch. If you can't get there from the link just google Lock-n-roll Under; Learn More

[dieseldoc]

Nice hitch!
I will have to pass that along to a friend of mine for his overland rigs!

[JandDGreens]

Cut the front off today I will be shortening the cab by about a foot. I know it doesn't seem like it would be worth the trouble but I think it being that much shorter will make it easier to go deeper into the back country. (at least that is the plan).

[JandDGreens]

Well making some progress, and went to the junk yard looking for a over head console for my XJ (anyone have a '97-2003 Ford F-150 overhead console you don't need?) ay way found some great doors for this project.
I have it ready to weld back together.

[JandDGreens]

Doors

[Rick]

:thumb:

[JandDGreens]

Fit the doors in so that I can figure out How to cut up the front doors to make things work. Also made the Child locks so that they can't be set.

[JandDGreens]

Went ahead and priced several things with a couple companies. I'm sure there are several things that will get added to the list before I actually order though.

[coleman07]

Dave,

Very Very Impressive. I use to take bicycles apart and put them back together ha ha - I don't have the Stamina for these projects anymore.

Sean

[wolfbuzz]

This is super cool; keep up the hard work.

[JandDGreens]

Up-Date I am making some progress on the camper. Welding frame for the floor and sheeting the underneath with 1/8 inch sheet metal I found in the scrap yard at C.M. metal. This is how far I got till the snow storm interrupted things.

[78bj40]

Looks like you making good progress!!! Keep up the good work

[Fordguy77]

Very nice work! Im surprised you went through the effort of cooping all that tube steal!

[JandDGreens]

Very nice work! Im surprised you went through the effort of cooping all that tube steal!

Yeah I wanted to be able to keep it as straight and flat as possible while I welded it up. It is going to be a bear to fit back under the cab.

[JandDGreens]

Here is a little progress report,
Now I need to start framing in the front and sheet metal the wheel wells down to the sub floor.

[JandDGreens]

Some goodies arrived today!!
I decided to go with a different coupler it is call Max Coupler (The reason being I have an adjustable trailer hitch which will work with this one)

[dieseldoc]

Nice work.
Keep it going.

[xaza]

That's nice, if you decide to pull it behind something setting at a different height it is as simple as getting a different basic drop bar. I thought lok'n'roll had an adjustable option too, been a while since I looked. Wish I could get things accomplished at a rate like you have been, looks sweet.

[JandDGreens]

They do but it runs about $125 extra, and this coupler will mount to any drop bar. I already have a adjustable drop bar like the one Rock-n-Roll sells. so I can use that to tow with any other vehicle, but for my XJ I'll get the right one. Also at the dealer I bought mine I can get an extra half that bolts to it if I wanted to. They sell both vehicle/and trailer sides separately. The other thing was this one got better reviews.

[JandDGreens]

Haven't had much time to work on this but here is how the front end is shaping up.

[Funrover]

Way cool! Been toying with the idea of doing this with a Rover

[dieseldoc]

Very nice work.

[newracer]

Why not put the windshield back in?

[JandDGreens]

Just want to close it in and make it stronger up front. The rest of the window will go back in once it's painted.

[JandDGreens]

So after our trail run at Halfmoon Creek I got the bug to get working on my trailer. I ordered a body bushing set for a Chevy Impala off E-Bay. I cut out some mounting brackets. Going to start on the frame soon.

[JandDGreens]

Made some progress this week. Starting to build the frame for the trailer. here's a few pics. once it's all tacked-up I'll pull it out and weld er up.

[BackwoodsRamblr]

Very cool!

[JandDGreens]

So I pledged most of my day to working on my frame. Pretty stoked with my progress I made to day.

[dieseldoc]

I hope you are putting a few more cross members in it.
Like 2 would be just right.

Better to over build than under!

[JandDGreens]

Yeah I have some angle iron that I will weld in for cross members on all the corners. I will do those after I have the mounts figured out. I am a little concerned that tongue is not long enough but have what I would take to add length to it. When we need it longer.

[dieseldoc]

Cool, I would make changes now.
You have it so you can get to all welds and such.
Or you can fish plate when add.

Its looking good.

[JandDGreens]

Yeah it was nice to be able to have it out in the open. I was able to stand it on end to get a nice flat run for a lot of the beads. I am working on it some this morning just taking a lunch break. I have expanded metal left over from a project I did for my lawn trailer for the tongue

[JandDGreens]

Today I made the tongue extension so that when I need to have more turning radius I can put it in and go. Got the expanded metal ready to go once I add the angle iron braces.

[dieseldoc]

Looks good David.

[JandDGreens]

So it seems that after I get the chance to do some wheeling I get the bug to work on my trailer. But before I could work on it I had to replace the u-joint on my front drive shaft. During the weekend I noticed a clanking noise and limped home on it and fixed it yesterday and preceded to get to work on the camper. I needed to plate the areas where the mounts were going. Then I had to mock-up the frame with the body and the axle. The camper might end up right at the height of my XJ which should be nice driving down the highway. Now it is time to tack the body mounts in place and get them welded up.

[JandDGreens]

Got some more done to the frame since the last up-date.
The frame is up side down in these photos. The pvc pipe is for the trailer wires going back to the tail lights

[dieseldoc]

Looking good David
Nice touch for the wiring.

[DETN8R]

I like how the trailer is coming along.
I recently had the idea to turn my sidekick into a trailer. Going to be following your build closely.

[JandDGreens]

Thanks I'm sorry it's going so slow, I only work on it in my spare time. I need to take some pics, of how the jack turned out. To be honest I am not sure it will work out, but if it does I will like the way I can remove it a stow it out of the way when I am wheeling and also lock it in place to make theft a little harder. I am so close to applying POR-15 to it, just want to make sue there is nothing I need to do to it before the finish goes on, I'll update with Pics soon.

[dieseldoc]

Sounds like you are plugging along.

[JandDGreens]

Got the chance to mess with the frame a little, Took some pics of the trailer jack mount and how the lock works on it.

[dieseldoc]

Nice. You will like having it movable!

[78bj40]

Looks good David, keep up the good work

[JandDGreens]

Thanks guys, will get to work on it today since the weather is going to give me a day off.

[Cr33p3r]

Looks great so far.

[JandDGreens]

I took a chance on the weather and decided to go ahead and apply the PRO-15 on the sub-frame today. Took longer than expected so I am glade the weather is mild enough that it will probable be OK curing over night.

[dieseldoc]

Nice to see paint going on.

[JandDGreens]

I went ahead and mounted the axle under the frame. I am stoked at the clearance it will have (other than the axle), it will be very similar to my xj's clearance.

[JandDGreens]

I am done with the remodel work on the house for the rest of the winter. Now I can concentrate on the trailer from here on till spring. Did some work the last couple of days.

[JandDGreens]

Now just have to get the other side done Get it tacked in and seal it shut get the other side ready and the I can take the sheet metal around the front so we can get it marked so I can bring the panels together.

[JandDGreens]

So today we put the frame and the body together. It worked out well.

[Patrolman]

Nice fit!

[Java]

:thumb: Really coming along well!!

[JandDGreens]

So even though I have had the time to work on this, I haven't done an up-dates for a while. (Really not to much to up-date) I have started the rear bumper/tire carrier. This will turn out pretty heavy but I am not to concerned as I need a lot of counter weight. It will have dual swing outs for tire/jerry and water cans. and also a couple drop tables to help with setting up our kitchen. Anyways here is a rough draft and a few photos to go with it.

First I had to beef up the area where the bumper will mount.

[JandDGreens]

The start of the bumper. (tact-up and ready to burn mounts onto the bumper itself).

[JandDGreens]

Here are a few photos of some of the body work were the front panel fits to the door. The other side will go cleaner and easier.

[JandDGreens]

The door jams were the hardest part as getting in there with the mig gun was very tight. But that area is going to be out of sight. and with paint it will look a lot better.

[DETN8R]

Looking Good! I like the dual swingout on the tire carrier.

[Jim]

Perhaps I'm skipping the notes and am only looking at pix - why did you need to re-create door hinges and not use existing?

Nice to see the progress!

[JandDGreens]

Actually the rear door hinges are untouched, but to close things off in the door jamb around those hinges is very tight. And I had to piece it all together.

[goSlo]

That's looking great man!

Love that hitch too.

[JandDGreens]

Pretty stoked on how the bumper is coming along, The base is looking great and I would hate to be the one who runs into it. It is built like Fort Knox.

[JandDGreens]

The bumper is kind of taking shape.

[Getaklu]

Looks like you should be able to break it in this summer for sure.

[Java]

That's great!! :thumb: Some of the last pics look like you crashed an XJ partially through the garage door. :)

[JandDGreens]

Looks like you should be able to break it in this summer for sure.
I hope so but when spring is in full swing I get petty busy with work. And play. I have so much body and paint to complete. Once it is done I can at least take it down and get it inspected, titled and use. Then there is the interior. So actually getting use it this summer we will see. I am really building it so that we can travel more when I completely retire on a shoe string budget. (I.E. National Parks Glamping on the cheap instead of hotels) I just want it to be as nice as I can make it, so it might take a while.

[JandDGreens]

That's great!! :thumb: Some of the last pics look like you crashed an XJ partially through the garage door. :)

Yeah it does look so, but there is a couple of feet of space between the tongue and the door. I am pretty fortunate to have this garage it is as deep as it is wide. as it is. Once I finally get the body work completed I will clean up this big mess I have going on. I might even get to work on my rig inside again. As long as I keep the camper in the garage it remains rust free so I can seal and prime the entire thing at one shot once I get there. Then that is when the prep work for the paint job starts.
So all my wrenching is done on nice days in the back yard drive way, Last year we installed Marks 8.8 back there.

[kilby]

I'm a little late to this thread but it's SO rad! I've unofficially thought that when my old Discovery dies (not too soon i hope) I could do something like this with the back half of it. It would take ridiculous work, but the fact that you're making it happen is super cool! Can't wait to see the finished project.

[Funrover]

Sweet!

[DETN8R]

edit: Sorry for the wrong post.