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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.
Update: Julie and I finished the camper November 17, loaded it on the truck, and left home. I will finish up details of the building process and photos if and when we return from the maiden voyage.
December 19 update: We returned after a month on the road. With several areas with tough backroads, it was an effective shake down trip. I will have more later and I'll complete the camper build photos. Our major learning curve was the new truck. It has a computer that wants to tell you everything, lots of buttons to push, and several I have no idea what they do. But, I'm settled in my confidence that I'll never need to know what they do. The truck's computer said that we traveled 3112 miles, drove for 80 hours, and averaged 17 mpg. I still do most things the old fashion way. Our log book says we traveled 3112 miles and bought 191.32 gallons of fuel. That equals 16.27 mpg, not 17. We had one tank at 19 mpg and one tank at 13 mpg. The 13 mpg tank was much more fun than the 19 mpg tank. This is all on winter blend gasoline. Past experience says summer driving yields around 10% better mileage. Note: I've calibrated the truck's computer to the circumference of our new tires, and I've confirmed the accuracy with gps.
More later, but we're working on a quick turnaround. That "if" is still in play.
Here are photos of the completed camper. The table is in place and the Iceco chest refrigerator is in place across the front.
The drawers and cubbies are stocked.
Simple access to the fuses.
It passed the shake down trip with flying colors, exactly as we expected.
We are waiting for the cushions for the three seat tops to be delivered. Next up in the build documentation is sewing the new arctic/thermal pack for the sideliner.
The Iceco fridge is the same IndelB truckfridge chest fridge that we've used for years. It does its job well. The only change I see is updated controls and much less swing between inside temperatures when operating. The compressor runs more often for shorter periods of time and keeps the fridge at a constant set temperature.
December 23 update. We picked up the seat cushions at ATC today. Marty also helped with an electrical issue I did not figure out. Saved me a lot of time. Thanks Marty! Marty knows campers inside and out.
December 25 update. Our three seat cushions are installed.
We have two circuits for love lights, both switched right inside the rear door. One led strip is below the cabinet and the second is under the counter.
An update from back in October. One thing Julie and I abhor is unnecessary manmade light in the backcountry. We use minimal outside light at night, in fact, as much as possible, we allow our eyes to adjust and use no light. So, imagine how we reacted to a new truck that turns on cargo lights, parking lights, brake lights, reverse lights, interior lights (even plays a musical tune) every time you open a door or lock/unlock with the remote. “Can we just get a big backhoe and bury this damn truck and its lights!” We could not/would not live with this. There is no way for the owner (us) to turn off this function through available controls/settings in the vehicle. This had to change. After mind-numbing and unproductive Internet time, I took the only glimmer of hope I found – Forscan – and initially used it to calibrate the truck to the new tire circumference. Testing with GPS while driving at various speeds confirmed accuracy. Using Forscan, I searched through many modules until I found items called “police mode” and “silent mode.” In utter dread I was about to turn our new truck into a worthless brick with an unintended computer lobotomy, I changed items from “disable” to “enable.” This happened - in the instrument cluster display between (our '21 Ranger) the RPM and Speedometer that is controlled with the arrows on the upper left side of the steering wheel, this change added a new function. Now when I scroll to "Settings" and then "Vehicle" and scroll down through the options there is a new "Silent Mode" option with a box to the left that can be checked on or off with the center "OK". With "Silent Mode" checked our dreams come true. No more exterior lights, no more cargo light, no more interior lights. In silent mode everything operates normally once the key is turned on. Uncheck "Silent Mode" and the truck returns to its annoying old self. With silent mode, we can now responsibly camp in the backcountry and not disturb and anger Mother Nature.
Since I made several comments about the
21" bed depth on our new Ranger, I'll add an update. A friend who is an
automotive engineer (and a very experienced mountaineer) stopped by to
see the new truck and camper project. I asked about the evolution of
deeper truck beds. He explained about vehicle doors. The window is the
weakest area in the door. To make vehicles safer and get better crash
safety results, windows have become shorter in height. In pickups, the
window bottom usually corresponds with the top of the bed for a nice
visual line. So be happy with a deeper bed, it may save your life.
Update on building the thermal pack.
“Are we going to make it?” Julie asked on a regular basis as we built the camper interior. “I told cousin Sherry we’d be there before Thanksgiving.” I hate deadlines. I love working on projects, figuring out the details, and enjoy the process. Deadlines are a distraction. So poor Julie got my usual response, “We’ll see.” It drove her nuts. She lived a life as a school teacher with strict schedules and deadlines.
Cousin Sherry (and husband Thom) is a truly special and talented person. During her working years she had her own upholstery business. She still enjoys projects and offered to help put together a thermal pack for the inside of the sideliner. We had all the material and supplies on board when we left on 18 November. First stop was Cousin Sherry’s place in Oracle, Arizona. We’ve been down this thermal pack road before –
Building an Arctic – Cold Weather Pack
This time we were using new material and a couple of design/build changes. Four Wheel Campers kindly agreed to sell us the new quilted material they recently switched to for their thermal packs.
I went over with Sherry the design and measurements and we put together a plan with pen and paper. Old ways still get the job done right.
With this material, edge binding is used instead of a folded hem.
The major difference in our new design was initially cutting separate panels instead of one long piece for each side. Each panel was edge bond and Velcro sewn vertically for the openings over the windows.
We hung the panels in place to check fitment. The vertical Velcro held the panels together and kept everything square.
Next up was sewing the wide Velcro along the top that adheres to the Velcro strip on the sideliner. This also joined the individual panels together.
With the Velcro in place, we checked the fit again. It was looking great.
We made the pieces that tuck behind the lift panels longer and cut slits for the straps that capture the sideliner to the back of the lift panel so the sideliner folds in when the top is lowered. The slits were hemmed.
With the panels sewn together, it was a delicate dance to keep control of the bulk as work continued to sew button holes for the D-ring loops on the sideliner windows.
It took three days to get the project completed. The result is wonderful!
All of us are work/project oriented – instead of sitting on our butts and “visiting”, so this project made for a great get together for all of us. Thanks, Cousin Sherry, for all the help and wonderful friendship!
Sherry grabbed a photo of Julie and me the morning we left to continue on our maiden voyage.
Update on learning to use the new truck. One thing this truck has that I never would have considered buying, but I've found surprisingly useful, is power folding side rearview mirrors. Three times now we've been on narrow roads with encroaching vegetation- juniper, pinyon, creosote, Palo Verde, mesquite - and pushing that button really makes it easier to squeeze through, especially one time backing up.
Update 14 January 2025. We dropped by the ATC camper shop to have the guys inspect our final product. We shared with them how Julie is holding up the “technical end” of our adventures with apps on her smartphone. She monitors our battery health with Renogy’s DC Home app. The Iceco chest fridge is monitored with the Iceco app. We opted to use a Mopeka ultrasonic sensor on the bottom of our water tank. The phone app gives precise readout of water in the tank.
And yesterday we were able to get that long awaited photo of Marty with the camper.
The adventure continues. Please check back for updates.
