Monday, November 18, 2013

Building Our New Camper! - Part Two




We spent the morning of my birthday back down at All Terrain Campers. Our camper was upright and the frames for the sides were completed and ready to be joined to the main unit.










Jeff started in on the welding.






The ply for the cabover was put into place……………………………






………………………………and screwed to the frame along with a bead of sealant. It looked like all those holes I drilled were working out.






The frame was shaped around the front and screwed in place prior to welding the ends together.






Marty invited the Lady along for a quick trip to the flooring store to pick out what she wanted. That was pretty cool!

The roof was laid out over the frame and the long ribs were cut and arched.






This is a well designed and incredibly strong frame work.






There was lots of welding to get done.














Our new camper is really starting to take shape! But along with that, the ATC guys have to deal with a really anxious costumer. She is working on her patience and getting better. It’s just that she knows how much fun and adventure is out there.






We went over layout of our propane lines and the routing of wiring in the walls.






We enjoyed seeing our new interior taking shape. We will spend a lot of quality time inside this camper quickly becoming our new home away from home.











A big thank you to the ATC crew sharing the following photos of the roof construction.
The completed roof frame with the cross members in place.










The interior fabric is rolled out over the frame.






And is soon in place.






A view of the top of the roof with internal wiring in place.






Including the wires to the solar panel plug.






The aluminum sheeting is installed.










The crew at ATC have been wonderful to work with. How can you thank guys enough for providing a series of photos of the interior wiring and framing complete with measurements? They are just great people.






This camper build is so cool on so many levels from seeing it transform from a stack of tubing and lumber to become a camper to daydreaming about all the wonderful adventures ahead this camper will play a prominent role in. It is hard to contain our excitement.

I was back down at the factory to check on progress and make some decisions. It is hard to stay away and again I thank the guys for their patience with me and my curiosity.

All the 12V wiring has been routed in the walls.














The roof is ready for lift panels and to be installed on the main camper section.






The Lady’s choice of vinyl was laid out with the floor pattern.






It was a perfect fit.






What a difference a day makes.

The inside paneling has all been installed and the window/exterior openings have been cut out.










The insulation is in the walls and the aluminum siding is going on.






Also in place for a test fit is the rotopax mount on the rear wall. 






Brad and Chad continue with installing the siding.














The Yakima Tracks are in place on the roof along with the plug for the solar panel.










Marty and my attention went to the placement of the bottom board I will use to build our cabinet. It would help to get it laid out now for placement of the furnace and the propane box.

Brad helps out by double checking the dimensions and that it is square to the extension below from the floor pack. This will be my cabinet for two bottom drawers.




After we fit the furnace in its place, it is then pulled out and test fired and ran for awhile to burn off any oils.





My future work space has been established and the ATC guys got right on finishing up the siding and trim.





Pretty exciting, isn’t it! The Lady said this morning that all she’s been dreaming about is camper parts and cold mornings “out there” where we wake, alone, and wait for the sunrise.


The story continues here for Part Three

Building Our New Camper! - Part One



We have made the decision to get a new camper. Our first step is having a All Terrain Camper shell built. The guys at All Terrain are the best in the business. It's a small company that builds a great product. What I really like is that its the people who actually build the campers that are the ones answering the phone and our questions. Back when we were starting out and rebuilding our first camper, these guys were such a great help with materials, parts, and how to advice. Their record of service and attention to their costumers needs makes for loyal costumers like us. These guys are also fun and straight shooters. We are confident our new camper from All Terrain will hold up to our adventures and serve us very well.

I stopped by All Terrain on Oct 28th and caught a glimpse of the new camper in its infancy.
Here's the floor pack.



 

all the aluminum tubing ready to form the frame





and the ply board for the underside of the cabover section.






I was back down at ATC the end of last week. We removed our first camper to double check dimensions from all our notes. Measure twice, cut once.






When we started with a pop up camper 4 years ago, we were experienced outdoor people but had no experience at all with truck camper camping. We were learning everything from scratch, how all the systems operate, and how to tweak it all to fit our needs. With 236 nights spent in our first camper, we believe we’ve now got it dialed in. It works. We’re happy. We know what we want.

I want to thank Marty and Jeff at ATC for one of the best birthday gifts ever in allowing me to hang out and even help with the building of our new camper. Yup, I got to do some cutting, drill some holes, help muscle some plywood around, and work at not getting in the way. I do know my way around tools and equipment and am a follower of Red Green’s advice, “If the women don’t find you handsome, they should at least find you handy.”

Our new camper will be very close to the dimensions of our old camper. It fits the truck well and the roads we travel. Jeff talked us into an extra inch of width.

We started in on the floor pack.










The two sides are completed.






Jeff was busy at cutting aluminum and framing up the front of the camper. 






Then the welding began.






The bed board for the cabover section was cut to dimensions and ready.






Marty worked on the material for the lift panels.






And they were soon cut to size.






The pieces were moved over to the bench for assembly.






The six hinges were put together and cut to size.






The hinges were attached and the bracing added.










The oak was selected for the sliders and the bed pull. 






The back frame including the rear door placement was carefully laid out. Jeff gave expert advice on additional framing to properly support attaching and carrying a rotopax gas can on the back wall. Thanks Jeff!






The front frame and the three pieces of the floor pack were ready for assembly.






Jeff welded up the back frame.










The pieces were now ready to put together. This is starting to look like a camper!






Marty started in on getting everything lined up and put together.






It all came together.






Next, it needed to get painted. The Lady got to work with the roller.




She is both handsome and handy.





This is so much fun to watch the build unfold. 






We’ll keep this updated and hope you enjoy this also.


Continuing………click for Part Two