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Note: this post will be periodically updated as we make progress with this project.
A New Truck & Camper
September 9, 2024. Here’s a real surprise. Julie and I made a quick trip to eastern Oregon and purchased a new truck. Extended cab Ford Rangers with the FX4 package are hard to find. Our new truck is a 2021 with 17500 miles.
Yes, the very first thing Julie checked out were the lower control arms. During her part of the test drive I suggested she put her foot into the pedal. "Wow!" is what she said. Now back home, we went through all our options on making our All Terrain Camper - built for our 2003 Ranger - fit the new truck. All were problematic so we decided it best to put a new camper on it. We ordered a Bobcat shell today from Marty and I will build out another camper, pretty much duplicating our current set up.
This new rig and camper will last us into our nineties.
Also, a big thank you to the Wander the West members I asked for feedback and comments on their newer Ford Rangers before Julie and I went on the hunt for a new truck.
Our 2003 Ford Ranger FX4 Level II is in great shape. We just returned from a 2000-mile trip to Idaho and Colorado and I would not hesitate to hop in for a trip to anywhere in the US. We are thinking for the long term - how many years ahead do we want to continue with our adventuring - and figured it was time for a newer truck.
We bought it off the lot at a Ford dealership in Oregon. It is a preowned certified vehicle with a warranty - a warranty in many ways better than the warranty that comes with a new vehicle.
Yes, we put up with the stupid dealership sales tactics. At one time we excused ourselves from the negotiations, went outside but within sight, and belly laughed out loud.
As I said above, 2020-2023 extended cab with the FX4 package are hard to find. We had 5 possibilities - Oregon, Colorado, Ohio, Connecticut, New Jersey.
Julie's response during her test drive was very similar to mine - "This feels like driving our old truck." A big reason we liked and bought it.
I've crawled underneath it, popped the hood, and looked at the parts that matter. The rear axle and differential are very much like on the 2003, although the 2003 level II has a bit larger ring gear and thicker axles. This one has a locking differential. The old Ranger had a mechanical limited slip Torsen differential. We always were able to get where we wanted to go with it. The front axle is very similar but easier to service. I do like the coil spring suspension on the new truck as the torsion bar suspension on the 2003 hung down underneath the truck. The seats in the new truck are comfortable and supportive and were fine on the long drive home. I like our old seats - even after 274,000 miles - a bit better. The new truck has disc brakes all the way around. So does our old Ranger (DIY project). I've not yet driven it in 4x4 low with the 10-speed transmission. All the technology bells and whistles are okay, sometimes a chore to learn, does not get me much excited, but, as I said, are okay. I do like having new airbags and the side curtain bags out of the side of the new seats.
It's footprint on the ground is only slightly larger than the 2003. It is 1" longer wheelbase, and the width is 3" wider. I believe it will be able to maneuver in the tight places we go. It feels and looks like a larger truck. Much of this comes from the foolish height of the bedsides. This I do not like. The bedside depth is 21". The 2003 was the old standard of 17".
We both like the additional power and torque. How we like the 10-speed auto and the 2.3 ecoboost engine, time will tell. Without a load, I need to be very careful with the go pedal.
It looks just as clean and new as our 22-year-old truck. I'm a geezer, you know. Note – sometime in the near future when our new camper’s build is completed – our current truck and camper will be offered for sale.
September 30, 2024. Marty called and said they'd like to do a test fit of the camper to the bed of the new Ranger. We were down this morning. This also gave us all the opportunity to go over how I was going to lay out the interior and where I'd be wanting the exterior plumbing and interior wiring in the frame, and a few other minor items. This is the kind of service I love and why we are going with ATC because of the attention to detail and always dealing with the actual builders of the camper.
It was great to fine tune some of the layout. This greatly built up the excitement level.
Brad rolled the camper into place and ready for the lift with the forklift.
Marty joined in. There was a joke that Brad and Chad were able to get Marty into a uniform shirt.
It fit like a glove. We did all the measurements a few weeks back. I believe this is the first ATC for the new generation Ford Ranger with the 21" deep bed.
Starting at left front - Brad, Marty, Chad, Matt.
We then went to work on the layout that I will be doing for the interior of the camper.
Brad went over with me on additional framing placement. Yes, we are getting excited!
Oh, Julie baked a batch of chocolate chip cookies early this morning for Marty to take down with us.
October 7, 2024. In preparation for carrying the new camper Julie and I did a little Saturday wrenching. Out with the old and in with the new.
I went with Australian Dobinsons suspension because they have been making aftermarket suspensions for the International Ranger for years. I had a long talk with Tom at Main Line Overland in New England. They have experience with installing Dobinson on Rangers that carry FWC popup campers. Tom was very helpful with his recommendations, and, he told me, owns a Ranger.
The ride height is about 2.5" higher than stock without the camper aboard. I also am curious how much the camper weight compresses the new springs. Without the camper I do not find the ride too harsh and prefer it to the stock FX4 that felt too soft and bouncy to my liking. It now feels much more like our old 2003 Ranger.
October 14, 2024. Julie and I had two things to drop off at All Terrain Campers this morning. Actually - how could I forget - three things; Julie had fresh baked chocolate chip cookies for Marty. We noted the progress ATC has made on our new camper.
Later in October update: We got the call from ATC that Marty and the guys were ready to deliver the camper shell for Julie’s birthday. What a grand present (having it completed) for the Lady’s birthday! She was more than thrilled.
We arrived at the shop mid-morning.
The camper was up on jacks and Chad was finishing up two items – the door latch and the furnace exhaust vent.
We put together items we bought from ATC for the interior build – water tank, plumbing items, CO detector, an assortment of fasteners, drawer hangers, propane lines, and such.
As the crew was readying for loading it on the new Ranger, they added slats across the camper bottom to level it to the top of the bedsides as the truck bed was 3/8” deeper at the rear.
It was then time to load the camper.
It fit like a well-crafted glove.
It was time for photos. Matt, Chad, Julie, Brad. We will get a nice photo with Marty in the future. He was called away for some office work.
We were back home in the pines in the late afternoon.
Ever since we’d made the decision on a new truck and then, also, a new camper, Julie’s been anxious about whether it would fit in the garage. No amount of reassurance would calm her nerves. She had to see it for herself. She climbed up on a ladder to watch the top as I slowly pulled the truck into its place in the garage.
Happy birthday Julie!
26 October 2024. With the new camper home, off the truck, and outside the shop, it's time for us to go to work.
Here is the nearly blank canvas
With a start on the structure of the main cabinet, the Lady paints all the bare plywood.
Another day and more progress. These should be self-explanatory as you what we are doing.
November 2, 2024 update. We’ve made steady progress. The tops of our combination storage bins and seats are completed except for finish trim.
The oak trim for around our open cubbies in the main cabinet is assembled.
Our four drawers are partially completed.
We completed a portion of the cabinet face around the two hanging drawers. An old piece of plywood served as a temporary counter top for layout. First, we constructed a template and fitted the drawers. The final piece was then cut and mounted.
November 6, 2024. This morning our doc kindly gave us a greatly needed refill on our prescription to get away. Our new camper and truck are coming together, but our work continues.
The water tank is buttoned up, partially filled, and all connections pass the leak test.
The cabinet face is fitted, and work continues on the other end surrounding the two upper drawers.
The red oak drawer faces are glued in place.
And trimmed to final dimensions.
Oak trim pieces are receiving finish coats of polyurethane.
November 8, 2024. The oak trim is completed around the right side of the cabinet. The drawer latches were drilled and mounted and then removed for finish work. The solar panel is installed.
November 10, 2024. We are working on several small projects related to the camper. The drawers are finished and have all the hardware installed.
This morning, we finished wiring the truck to camper interface. We also did our first oil change on the new Ranger. The easiest access to the engine oil filter is through the left front wheel well with the tire removed. This allowed a photo of the front suspension wrenching – did not take photos at the time – and the install of beefier front springs and shocks.
November 11, 2024. I finished up wiring the battery, Renogy dual charge controller, and ran house power over to the fuse blocks for the various circuits. I only powered up the ceiling lights. What a difference it makes having a nicely lit work area.
I also ran the propane lines, tightened connections, charged the system, and checked for leaks. The propane system is ready.
Since we started this project, nearly every day the Lady has asked, “Do we put the counter in today?” I could delay her milestone no longer. It was time.
With it in place, we final checked the placement of the sink and stove and cut holes back inside the shop.
Accurate, well-cut holes; a milestone I’ve been waiting for. The counter went back in the camper. Next up on the project - we will wire all the circuits and install the furnace.
November 13, 2024. Julie completed finish sanding of the oak frame for the cabinet front. She moved on and got them stained.
I took care of boxing in the furnace enclosure, adding cold air in and warm air out ports. I also added switches that can be easily reached from outside the door.
The right side of the camper is mostly done. We await delivery
of three seat cushions.
We added a solid oak kick plate along the bottom of the seat boxes just inside the door. Julie apologizes for the shadow but I cannot complain. She has been taking most of the build process photos with her phone. Last up on this side is to install the table and table mount.
We installed the sink and stove into the counter.
We have fire!
Another day. All the wiring is completed, tested, and working as it should. It is almost time to button up the cabinet and install the face and trim.
I mentioned the furnace enclosure. All the switches are wired and working. The furnace is installed and fired up. It works!
We are more in need every day to take Doc up on that prescription.
The adventure continues. Please check back for updates.