jclures DIY crossover camper

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jclures
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Re: jclures DIY crossover camper

Unread post by jclures » June 14th, 2018, 7:05 am

I have been working on the first of two storage draws at the rear of the camper. I like to have a spot for things and then they can be easy to get when needed, that is why I planed these draws from the start of the build.
I have folded them from some of my leftover aluminium, so I can keep them as light as possible.
This drawer is for the tent pegs, hammer, Ropes double and single as well as the rope springs.
The springs have small shackles on each end, and the ropes have spring clips on them so I can break them down to pack away.
I still need to trim the door edging then this drawer and door are finished.
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jclures
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Re: jclures DIY crossover camper

Unread post by jclures » June 19th, 2018, 7:36 am

I have started to fix things I am not happy with, and the first fix is the hand brake.

From when I first fitted it, I have not been happy with the hand brake lever.
I thought was up at too high of an angle when the hand brake was off. It might not seem much, but when stepping over the A frame of the trailer, I was worried about tripping on the lever.
Hand Brake lever 002.jpg
To fix the height when off, it needed a couple of new teeth cut and a relocation of the roll pin stop. Now the handle sits level when off, not up at the angle it was.
Hand Brake lever 003.jpg
I also thought it took too much force to pull the hand brake on, I had to pull it quite hard to stop the camper from being able to roll off.
As I had already used the closest hole to the lever pivot, I have drilled an extra hole. This has reduced the force needed to pull it on. Not much of a change to do, but much better operation for the hand brake.
Hand Brake lever 001.jpg
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jclures
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Re: jclures DIY crossover camper

Unread post by jclures » June 26th, 2018, 8:46 am

I am getting the camper ready for it's next trip, so there are a few bits I would like to get done.
The first job I have finished is the kitchen drawers. I did make temporary drawer runner frames to work out what I wanted, which I now have replaced with folded aluminium drawers, and drawer fronts.
I have also lined the bottom of the drawers with a light soft rubber sheeting, this I hope, is to stop any rubbing on the aluminium drawer base.
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ian.gonzo
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Re: jclures DIY crossover camper

Unread post by ian.gonzo » June 28th, 2018, 12:34 pm

Looks very professional

jclures
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Re: jclures DIY crossover camper

Unread post by jclures » June 30th, 2018, 2:39 pm

Thanks Ian.

Even though the kitchen drawer runners have a 225kg rating, I thought I should support the kitchen when out.
I wanted a simple leg which can be fitted when needed, and to be adjustable.
I had a swing down leg which was damaged, so after removing the damaged swing down part I have made a two stage adjustable leg.
I should be able to knead bread or do anything I want now on the kitchen bench without any movement at all.
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jclures
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Re: jclures DIY crossover camper

Unread post by jclures » July 6th, 2018, 9:45 pm

This week I have been reworking a few things. The first job to do is my compressor setup, I have had the Thor Air Compressor here for some time now ready to fit.
After testing I have decided to leave the compressor I have, and run the new one along side it. Each compressor has it's own airline to the tank with a check valve each as well. Before the new compressor it took around 5 minutes to pump the 9ltr tank to 120psi. I never timed it to 150psi which I want it to be set at.
With the two compressors now running with the tank empty it only took only a fraction over two minutes to shut off at 150psi.
Thor air comp fitted 01.jpg
The other job done was easy, I wanted a easy garbage bag setup. I went into BFC and brought a Croc Bin. All I needed to do is work out where I wanted to mount it, just need to take it off before breaking camp though.
bin bag holder 01.jpg
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jclures
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Re: jclures DIY crossover camper

Unread post by jclures » December 20th, 2018, 10:16 am

After several short trips with the camper, I am not happy with the suspension. I have for me, had too much role on the airbag suspension, so I have decided to redesign it.

I designed the chassis around these air bags, they were what I had to start with, if I can get it right they should be good off road, as there is around 9” travel.

I am moving the air bag closer to the wheel on each side by about 50mm. I am also adding a second set of air bags beside it. My thinking this should reduce the air pressure in them while travelling and make it more stable.

I was running around 145psi in the air bags Before, with two each side this now should be halved or there about. Also twice the surface area now for support although with the inside air bags this is diminished a little due to the leverage of the suspension. (I think)

I ended up building a new axle completely, it was easier this way. I took a leaf out of a build I saw on another trailer build on another forum, and welded my brackets to a second box section then welded it the to the axle.

I am also now using a 60 series Toyota rear sway bar as well, it is wide enough to have the link arms either side of the water tank, this alone should help as it is a lot stronger sway bar than I had before.
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jclures
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Re: jclures DIY crossover camper

Unread post by jclures » December 20th, 2018, 10:43 am

I also had a look at the water tanks while they were out. When I first fitted the tanks, I brought water level senders which I had fitted. These have given me a problems with the water leaking around the sender tank seal.
I think the tank wall thickness is to thick for the sender, so I have changed the way the sender is fitted.

I brought two screw covers used for boats, cut a hole in the top of the tanks and fitted the screw covers.
Then after cutting of the plug to the display unit, (I had to do this to get the nut washer and seal of the sender unit, it also let me trim of the excess length of wire)I then rearranged the washer, seal and lastly nut after fitting the sender in the tank. I then soldered the wiring to the plug back on.

There is no leaks now and the senders can't fall out.
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jclures
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Re: jclures DIY crossover camper

Unread post by jclures » December 20th, 2018, 10:53 am

As I have finished the new air bag design, it is time to get on with some fitting in the camper and the Nisota.
I wanted a camera on the rear of the camper, so I have gone to a Digital Wireless System. This was not the cheapest or the most expensive, but it should work for me.
The receiver monitor can run up to four cameras, which at present I only have two. One of these has been fitted to the rear of the camper and the other on my Nissan.
I an still to work out where to fit the monitor, as well as the phone, which is only used as a gps and mapping device.
I have also started putting the carpet in the camper under the bed, and on the battery box lids.
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Boxhead 71
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Re: jclures DIY crossover camper

Unread post by Boxhead 71 » December 31st, 2018, 10:09 pm

Looking good mate. 👍
How much was the flooring?
We have just bought a small camper/van/teardrop thingy that isn't finished on the inside. Have really only looked at Bunnings stuff at the minute.

jclures
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Re: jclures DIY crossover camper

Unread post by jclures » January 4th, 2019, 11:02 pm


jclures
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Re: jclures DIY crossover camper

Unread post by jclures » January 20th, 2019, 8:11 am

I brought these two batteries for the camper for its Christmas present, but before I fitted them I needed to get the wiring for them done as well.
130 ah batteries.jpg
With using my cpap machine, the more storage I have gives me more options travelling. I would like not to need any extra charging other than what is built into the camper and Nissan.
I already had two 90ah batteries fitted and with these two that will give me in total around 440ah. That should be around 4 day night trips even in wet weather with little or no solar input.
I had always planed on having four batteries, so the fitting them in was the easy bit.

After a bit of reading on charging battery banks I came up with my wiring diagram, but keeping it as modular as possible, letting me remove, replace or upgrade as needed. This also included the c/b boards which I had fitted but not finished.
130 ah batteries.jpg
left cb board.jpg
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jclures
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Re: jclures DIY crossover camper

Unread post by jclures » March 18th, 2019, 8:05 am

I am still having problems posting photos, so I will try again to update the build later.

jclures
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Re: jclures DIY crossover camper

Unread post by jclures » April 4th, 2019, 10:05 pm

We went out camping for the weekend, Nisota and Robustus together.

https://www.youtube.com/watch?v=WYwKLdfUU3o

Peter Aawen
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Re: jclures DIY crossover camper

Unread post by Peter Aawen » April 4th, 2019, 10:28 pm

Pse see my comment in the Nisota thread. :) And they're STILL lookin' Good! ;)
An Ex-Service person is someone who thought enough about their country & how great it is, how lucky we are to live here, to write a blank cheque made out to 'The People and Commonwealth of Australia' for the value of 'Up to & including my Life!'

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