ARE Shell Build-Out

[scooterdog]

Weather reached the 40 degree mark, so we were able to do some more work on the truck.  We installed the back wall panel, the partition panel and one bed w/potty.  Today, hope to get to the back shelf and second bed.  Come on Sun!

 

[Queen]

That is looking super, brilliant idea on that privacy shield!

 

[scooterdog]

Rear shelf is installed.  It is 18 inches deep and 40" wide.  Planning to use it for clothing, time will tell.

Each sleeping compartment has a LED light and cargo netting storage.
A CO detector on the passenger side and a Smoke Detector on the driver side, must keep the spouses happy.

 

[SoulRaven]

Okey dokey, between the bitter temps and recovering from the flu, things have been slow on the build.  Yesterday we finished installing the poly-iso insulation.  The poly-iso panels were cut to be a tad to big and then pushed into the areas between the aluminum framing.  Taped off with extreme weather foil tape.  Happy with the results and the sides of the camper sound pretty solid when you knock on them now.

Can you please provide more detailed info on what type/brand/size of the poly iso and the tape you used and what vendor that would have these products in stock?

Plus where did you get that puzzle connected flooring?

 

[scooterdog]

Can you please provide more detailed info on what type/brand/size of the poly iso and the tape you used and what vendor that would have these products in stock?

Plus where did you get that puzzle connected flooring?

I got the poly iso foam boards (4 x 8) at Lowe's Home Improvement Store.  Sorry, I don't have the SKU #,  it is in the insulation aisle.  Look for the board with the silver backing.

The tape is 207/8 inch x 50 yards Extreme Weather HVAC Foil tape (internet number 100507541), which I special ordered from http://www.homedepot.com

I ran out of this tape, and went to a local HVAC supplier and bought their version of the Extreme Weather HVAC tape.  I like the Home Depot version better, as it is plain silver tape.  The local HVAC supplier has the logo of the tape maker all over it.

The foam puzzle floor can be found at Walmart, Meijer's and maybe Target. They never have it shelved in the same place twice. I have found it in the baby equipment, work out supplies and, once, in the automotive section. Go figure?

Hope this helps, I enjoying reading your blog. I appreciated how quickly you responded to my question I asked you on your blog.

 

[SoulRaven]

Mr. Dog what is the thickness of the iso foam board you used.

My truck cap is much like yours and I need a product that will handle the curves.

How many rolls of tape did you need/use?

Thanks for the kind words and good luck on your expedition.

 

[akrvbob]

Sorry, but the picture didn't make it clear to me so a couple of questions; is the shelf on the wall behind the truck cab and goes across the bed? How far below the roof is it? How did you mount it to the shell?

Can I be pushy and ask for a picture from a side angle to give me a better idea of what it is?
Bob

 

[scooterdog]

Mr. Dog what is the thickness of the iso foam board you used.

My truck cap is much like yours and I need a product that will handle the curves.

How many rolls of tape did you need/use?

Thanks for the kind words and good luck on your expedition.

I used one layer of the iso foam board,  which is 1 inch thick.  Before I used the iso foam, I covered my inner camper top with Peel & Seal.  The Peel and Seal worked great as a sound damper and vapor barrier. 

I used a Framers Square to aid in cutting "square" panels and a utility knife.  I cut the panels just a tad bigger than the measurements.  I gently squeezed the cut panels between the aluminum frame of the camper.  The iso panels sit flush with the aluminum frame of the camper, leaving a dead air space between the Peel & Seal and the  iso foam board.

The curved part of the camper required scoring lines on the back (the side which does not have the shiny layer on it) of the iso foam board.  I set the utility knife to cut no deeper than half way through the iso foam.  Scored the cuts parallel to the longest side of the panel I was cutting, or horizontal to the floor of the truck.  Pressed the cut panels into place, shiny side toward the inside of the cabin, by pushing gently on the area where I guessed the lines were located behind the panel.  I started pressing on the bottom line and worked my way up.  The panels snapped right into place and followed the curves of the camper top.

Finished it off with taping all the seams, I used 1 and 1/3 rolls of tape. The finished job looks great!

 

[scooterdog]

Sorry, but the picture didn't make it clear to me so a couple of questions; is the shelf on the wall behind the truck cab and goes across the bed? How far below the roof is it? How did you mount it to the shell?

Can I be pushy and ask for a picture from a side angle to give me a better idea of what it is?
Bob

Bob, it is dark and 19 degrees outside.  I will get ya some pics when it warms up

The back panel is not attached to the shell.  The back panel and the partition panel are screwed together where they join.  Both panels are affixed to the wooden bed frames via lag bolts.  The wooden bed frames are screwed into the "locking" plywood floor panel.  I refer to it as the "locking" plywood panel because it is cut to snuggly follow the floor of the bed of the truck, thus "locking" it into place.  The plywood floor is anchored to my truck tie downs, also.  I needed to make this removable, so nothing involving the beds are the panels are directly attached to the truck or the truck cap.

 As you can see by the photo, the "floor" fits around the wheel wells, locking the "floor" into place.  The floor can not move forward, backward or side to side. 




The shelf goes across the bed, at the head end.  The distance from the shelf to the top of the camper shell is about 12 inches.  The shelf is screwed into the top of the "back" panel and the partition panel.  The partition panel is cut out to accept the shelf.  I used Kreg Joinery to attach the shelf to both pieces.  I don't know if you are familiar with pocket joinery or Kreg Joinery, but it is a nifty little jig which allows you to butt two pieces of wood together and hide the screw heads.  It forms a very strong joint. 

The edge of the back of the shelf does not directly touch the back of the camper top.  There is about a 1 1/2 inch gap between the shelf and the camper shell. I used foam pipe insulation as a buffer between the back of the shelf and the the back of the camper top.

Photos to follow ...

 

[akrvbob]

Thanks!
Bob

 

[scooterdog]

photos ....


Camera angle taken while laying on the passenger side bed and looking up.  You can see the shelf supports which are screwed directly into the back and partition wall.  The shelf was placed on the top of the back wall, the supports and the cut through of the partition.  Screws were drilled upward into the shelf and through the supports. 




looking down the partition wall toward the cab of the truck.  Just another shot of the shelf supports.




Camera angle taken from the end of the shelf on the passenger side, looking toward the end of the shelf on the drivers side.


Shelf is 18" deep and 40 inches wide and 8 inches high.  I incorrectly listed it as 12 inches high in a previous post.  Hope this helps you visualize it.

 

[akrvbob]

Got it!! A picture really is worth a 1000 words!

I think your shell is going to work really well for you!
Bob

 

[scooterdog]

Ok, the basic structure is finished, on to accessories!

The camper has a roof vent, a sliding rear window and both side windows open fully.  I am concerned with condensation, so the plan is to open the roof vent and the sliding rear window at night.  The camper windows and doors will be locked up tight.  The fans are 12 volt boat fans, with a very low battery draw.  Installed two fans.

 

[akrvbob]

The pic must be a close-up--it looks enormous!! You're not worried about having the blade uncovered? I assume it must be plastic.
Bob

 

[highdesertranger]

if that's the fan I am thinking of they have soft rubber like blades. highdesertranger

 

[scooterdog]

The fans do look enormous, lol. They are a pair of very nice Caframo 12v Boat Fans. These fans only draw .5 Amps at high speed.  They have a 2 speed switch and directional base.  I am using the cigarette lighter plug they came with stock.  Blades are soft plastic, won't hurt you if you get into them.

Here is another angle, they really are mounted out of the way.

The "builders" are taking a well deserved rest, I'm on the passenger side and my buddy, Sue, is on the driver's side.  Cushions, screens and curtains to follow.

 

[LeeRevell]

Y'all have more room than I thought earlier. Good to have a pic with warm bodies to give perspective!

 

[SoulRaven]

I thought that two men where going to spend the summer in Alaska in a truck cap and a scene in a movie came to mind.

But I am relieved that there is a partition in place and the name of your “buddy”, for I would not want you to play the role that helped to make Jake Gyllenhaal famous.

 

[scooterdog]

Yep, plenty of room.  Sometimes it pays to be vertically challenged.

 

[akrvbob]

Looking very, very good. You're going to have a great trip!
Where did you get the organizers at the foot of the bed?
Bob