Our new popup camper

[Robinhood4x4]

For the past year, the wife and I have been tossing around the idea of getting a popup camper to take to the mountains around here. Free camping around here means staying on national forest land but the wife insists on having a bathroom nearby, even if it's a pit style bathroom. Well, everybody else in the valley, who are trying to escape the heat, have the same idea so that also means we're surrounded by idiots. So our solution was to get a camper so we can get out to the middle of nowhere on national forest land.

After about a month of searching craigslist and visiting the local RV dealers, we finally found a really nice camper that was perfect for us. This is a 2003 Coleman/Fleetwood Taos.

http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/IMG_9796s.jpg

It's pretty much the smallest modern camper made which is exactly what I wanted for the trails. The previous owner did a SOA conversion to give it a small lift. As it sits now, I have 1.5 feet of clearance between the ground and the frame.

http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/IMG_9798s.jpg

I'll probably end up doing a couple inch block lift and maybe put bigger car tires on. It also definitely needs armor.

http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/2003Taos_entryclosed.jpg

Other possible mods include a larger water tank (existing is 5 gallons), water heater, shower, electric water pump, propane heater, residential wood flooring.

Here's the interior:
http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/2003Taos_inside1.jpg

http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/2003Taos_inside2.jpg

It'll be a challenge to figure out where to put everything, but I think I can do it.

Oh, and the ruffled curtain hanging thingies have got to go.

One last pic of the back.
http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/IMG_9801s.jpg

[4x4mike]

I like it. Now with a 2 year old and another on the way I think it would nice to have a little trailer. Yours appears to be in great shape and a nice compact size.

Does the sink work from a foot pump? You mentioned no pump which might mean no wiring.

If I had one I'd mod the heck out of it with LED's, sink/outside shower and outside BBQ of sorts. If there is space a larger water tank might be nice but 5 gallons might be a good size, just bring jugs to fill it up. Is the current tank inside the trailer or under in the frame rails? If it's under I'm sure space is limited not to mention vulnerable to rocks.

[Marc P]

That is a nice little one...we have a Coleman Nevada. I am not sure I can tent camp again.

[Ric]

very nice, I remember the first 4runner jambo we went to out here, we did the tent thing, well it rained one night, it was cold and wet, wasnt fun at all, the next year we reanted a pop-up, and yes it rained again, but WOOOW what a difference, everything was warm and dry, made for a GREAT weekend.

Well since then, Ive set up runner to sleep out of it, but it still doesnt compair to a pop-up but for the now single guy, it works great, lol

Does yours have the shower thing on the side ?

Congrads on the new toy, you are going to love it.

[paddlenbike]

Very nice. I had a Fourwheel Pop-Up camper (not trailer) and sold it after 8 months of use. Besides having to choose between driving around with it on the truck all the time or constantly loading and unloading it, it's biggest downside was the fact that you would get to camp, get it level and everything setup for camping, then you'd need to drive somewhere. I swore next time I did it I would buy a pop up trailer instead so I can setup camp, disconnect the thing and have the 4Runner to drive around. It's so nice to have a cushioned bed and hot water. And these are so small and light they aren't a burden to tow. Congrats!

[Robinhood4x4]

That little knob looking thing on the sink is actually the hand pump. You just pull it up and push it down and it pumps water. There is some electrical but only for 120V AC when it's plugged into electrical service, and also 12V DC for the overhead lights and gas leak monitor.

I hear you on modding it with LEDs and they're on the list for the interior and exterior. I want to put some outside flood lights on the roof for setup, some reverse lights (amazingly, there are no reverse lights),and maybe some "rock lights" to help with leveling and stabilizer setup.

The stove can be moved to a removable shelf that attaches right beside the door on the outside. It shouldn't be too hard to plumb in our weber gas bbq to fit in the same area. There's already a gas line with quick disconnect that go to that area.

Five gallons would probably be ok for a few days if nobody takes a shower, but I think we would need more if they do take showers.

What some people do for showers is attached a large plastic tub to the floor under the seats, plumb in a drain and hang a shower curtain from the ceiling. The water tank for the sink sits right under the sink, not underneath. I was going to hang a fresh water tank and a holding tank underneath, but then I got to thinking if it gets really cold, the water would freeze, so I'm not sure what I'm going to do there.

Ric, currently, the wife and I setup a tent and put all our stuff in it, while we sleep in the truck too. Sleeping in the truck is the way to go. No shower thing on the outside.

[Robinhood4x4]

Ken, that's the same reason I don't like the truck bed tents. If you need to go anywhere, you have to take it all down.

This one weighs in at 1200 lbs and I can barely feel it. It has electric brakes, but I don't have a controller yet and I couldn't tell it was there. However, a controller will be one of the first things I buy.

[Intrepidyota]

One thing I love about my popup is that we leave everything in there except for a rubbermaid tub of consumable items and another for food. So when we want to go out, we just pack up food and clothes and we are ready to go as soon as we can hitch up.

Check out www.popupportal.com (http://www.popupportal.com), its not hardcore offroad trailer stuff, but they have a lot of good ideas for storage, battery power, and small modifications for convenience.

[Robinhood4x4]

That's our plan too...keep most thing in there and just hitch up and go.

I'm already a member there and have to chuckle at some of their mods and some people's idea of camping. When I start modifying mine, I'll have a build thread over there and here.

[Seanz0rz]

i love it!

alexus and i are really interested in picking one up. i would of course probably throw a new frame under it and modify it for dirt road / light trail use.

that one looks mighty nice!

if you dont mind my asking, how much did you pay (ballpark)? we are looking at a pretty low cost of entry, so i dont think ill get anything nearly as new as what you have.

[Robinhood4x4]

I don't think this one needs a new frame, just maybe some reinforcement in key locations and removal of some members to clear bigger tires. If I remember right, I think all colemans have a fully boxed frame, at least I know mine does.

Other than a lift, I think it could use some softer suspension and damping to help with washboard roads. Washboard roads will kill the interior. Even the guy we bought it from said he's had to go through and tighten the screws holding the cabinets together.

The stock suspension uses these tiny little leaf springs with no shackles and no shocks. It gets its damping from the back of the leaf spring rubbing on the frame. Going with car tires and airing down would help a lot too.

We picked it up for $2300. It seems like these coleman taos campers go for around $2500 and even right now, there is a 97 here in phx for sale for $2300.

If you want to restore one, you can pick one up for as little as a few hundred dollars. The biggest expense would be new canvas and you're looking at $1000-$1500. There are a few projects on the popupportal where they are doing frame off restorations and it seems pretty straight forward. It also seems like prices in california are better than the phoenix area. I missed a fully loaded taos in san diego for $1900.

Keep in mind that these trailers are pretty wide and it would be tough to get one through rock crawling trails. Having said that, I've got ideas for some armor.

[Marc P]

I have been having trouble with the doors on mine...the lock on the stepper door broke on out last trip and I drove it home with ratchet straps around the whole thing.

Mine is big and heavy too, 4runner hates pulling it up the hills.

http://i21.photobucket.com/albums/b251/MarcP1971/0109011325.jpg

[^VooDoo^]

change springs, Use shocks to stop fishtailing and lower washboard rattle.
Maybe airlift, Run it lower profile on the highway and raise it for the trail, Also makes it quick to put on and take off the corner jacks.

[Robinhood4x4]

That camper is huge, Marc. Where does the door go?

[Scuba]

Looks great. I'm a little jealous!

[paddlenbike]

This is a little OT, but there are some pretty fancy tent trailers available in other countries. I like the European way of traveling small and light. Check this thing out:
http://blog.flying-hobby.com/wp-content/uploads/2011/10/sydney-opera-house-inspired-Modern-Pop-Up-Camper-04-300x158.jpg

http://media.treehugger.com/assets/images/2011/10/opera-closed.jpg

http://blog.flying-hobby.com/wp-content/uploads/2011/10/sydney-opera-house-inspired-Modern-Pop-Up-Camper-08-300x158.jpg

http://blog.flying-hobby.com/wp-content/uploads/2011/10/sydney-opera-house-inspired-Modern-Pop-Up-Camper-03-296x300.jpg

[Obi..]

WANT!! :D

[MTL_4runner]

Whoa, that's pretty sweet!

[paddlenbike]

I am anxious to see your build thread. Lift, larger tires, better suspension, awnings, LEDs galore... :)

[Robinhood4x4]

Thanks. I need to hit the local trailer places to see about bigger axles and what my options are to get truck tires on there. Axles themselves seem pretty cheap as it looks like I can get a 2000 lb axle for about $100-150.

The first order of business, however, is to make a "fence" for the side yard so that people walking behind the house can't see it. I have a view lot and technically, I'm not supposed to have a trailer back there, I think.

[04 Rocko Taco]

Put it in the driveway.
If someone told me what I could and could not have on my property. I'd move...

...Or kill them.:hillbill:

[paddlenbike]

Alright, it has been several months now, is that puppy decked out in LEDs yet? :D

http://www.southerncrosscampertrailers.com.au/img/uploads/extras/large/20110805131458_1.jpg

http://media.tecca.com/2012/01/24/th21-630-led-rv-630w.jpg

[Robinhood4x4]

Sorry for the late reply Ken, I saw your post the first day but have been super busy lately.

No lights yet and not too many other mods either. With my limited free time and the impending summer approaching in just a few months, I've had to pick and choose my projects and priorities. The first thing that had to be done was figure out the toilet situation for the wife. Thetford makes a toilet that fits perfectly in the little storage area by the door.
http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/2003Taos_inside2.jpg

But me being me, I couldn't leave well enough alone and had to have the bigger one so I wouldn't have to worry as much about extended camping. So in order to fit the bigger portipotty in the same space, the plan was to make the whole cupboard removable.

Well, the flimsy wood and particle board structure wouldn't repeated removal so I had to beef it up some. I welded up a steel frame and bolted everything together with (54) 6-32 screws. :D
http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/IMG_1403.jpg

It fits perfectly.
http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/IMG_1405.jpg

http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/P1090266.jpg

http://i1232.photobucket.com/albums/ff380/antinode4x4/Popup%20camper/P1090267.jpg

This baby is so strong, you could almost use it for a stand alone chair!

I'm not sure what the next mod will be, but I need to install a Wave heater, which is like a mister buddy, but much bigger. I also have an idea to fit a shower in there too. Before that, I think the priority will be to add an electric water pump, real sink faucets, and a water heater.

Water storage tanks are expensive though, both fresh water and grey water tanks.

I know, not the sexy mods you were thinking of, but first things first.

[paddlenbike]

Good stuff Steve! My favorite threads on these forums is watching progress; whether its on a truck, house, RV, whatever. I look forward to reading about your summer travels, hopefully it involves another get-together in Mammoth.

[Robinhood4x4]

Ok, after a couple camping trips under my belt now, I've started the journey. The first priority was new tires because I think the old ones were the original tires. Since everybody on the internet says trailer tires suck and they all blow out, I was bound and determined to get some LT tires under there. Here's what it would have looked like with my 30" stock tires off the 4th gen.

http://antinode.smugmug.com/photos/i-ZMD9hs7/0/XL/i-ZMD9hs7-XL.jpg

http://antinode.smugmug.com/photos/i-qxn3Jt7/0/XL/i-qxn3Jt7-XL.jpg

That would have taken a lot of work to get those things under there. The smallest LT tire I could find were 26" tires and even those would have been a stretch. Not impossible, but there was a strong possibility of needing to cut into the frame and outer skin for clearance. Reluctantly, I went with plan B, which was a set of Maxxis tires, which have a relatively good reputation for a trailer tire. This is where the second problem came in. The smallest tire they make is a 24" tire. Well, this would require larger wheels and about 1" more lift. What pushed me over the edge, was looking at the spring hanger welds. It must have been training day when they made my trailer because my little miniature schnauzer could have done better welds than whoever put mine together.

http://antinode.smugmug.com/photos/i-r3r4nVW/0/XL/i-r3r4nVW-XL.jpg

So I decided I would upgrade the suspension and use 1" taller hangers and shackles. Oh, and I found out my axle is actually a 2200lb axle, instead of the sticker that said 1750 lbs. It turns out the sticker was probably put there by Coleman because either the springs, wheels, or tires weren't rated for 2200 lbs.

The surgery started yesterday.

Here's one of the hangers cutoff. Like I said, the welder must have been new, or something.
http://antinode.smugmug.com/photos/i-bXRjM25/0/XL/i-bXRjM25-XL.jpg

Here's another hanger. They even blew a hole through the frame!
http://antinode.smugmug.com/photos/i-PHvbXjP/0/XL/i-PHvbXjP-XL.jpg

Another reason it was a good idea to re-do the suspension was because the previous owner simply flipped the axle under the springs, but turned the axle upside down. This axle has camber to it, meaning that when it's loaded, it's supposed to flex flat. Well, the shop that did it, reused the ubolts and even stripped one of the nuts. The axle was being held on by 3 out of the 4 U-bolts and they were all bent to hell.

That's as far as I got with the suspension, so on to the new wheels and tires. Those came in sooner than expected and because I had some left over wheel spray paint from the miata wheels that I never painted, I decided to go blingy. I painted the trailer wheels a metallic silver/gray, kinda like teflon color.

http://antinode.smugmug.com/photos/i-kW28MFh/0/XL/i-kW28MFh-XL.jpg
http://antinode.smugmug.com/photos/i-MKfdC2k/0/XL/i-MKfdC2k-XL.jpg

Here's a comparison of the size:
http://antinode.smugmug.com/photos/i-GZ83zT5/0/XL/i-GZ83zT5-XL.jpg
http://antinode.smugmug.com/photos/i-q33RCfk/0/XL/i-q33RCfk-XL.jpg

And here's what it'll look like when it's done:
http://antinode.smugmug.com/photos/i-9hV5Swh/0/XL/i-9hV5Swh-XL.jpg

Here's a teaser of phase 2:
http://antinode.smugmug.com/photos/i-btx5ST5/0/XL/i-btx5ST5-XL.jpg
http://antinode.smugmug.com/photos/i-TdFp2hJ/0/XL/i-TdFp2hJ-XL.jpg
http://www.amazon.com/Light-Heavy-Offroad-Trailer-degree/dp/B008CSHRL2/ref=?ie=UTF8&m=A7RNQ92KM0URZ

[4x4mike]

Mmmm, lights.

I've never been impressed with trailer welds or construction. Even big trailers that have large capacities. I tend to give them a little more room on the road.

I have a small utility trailer and I've gone through checking everything out. The welds look good but some things just look under sized. The springs, u bolts and perches are all very small. I don't use it much and it's only rated at 2,200 pounds but it gets the job done.

I'm excited to see your progress on your upgrades.

[paddlenbike]

Phase 1 was fun, looking forward to Phase 2.

It's nice to see some quality LED stuff hitting the market now. I don't have time to build everything myself.

[Robinhood4x4]

I think I have a total of 5 of those lights now and 2 with more LEDs so they're even brighter! You're definitely going to know which camp is mine! The two brighter ones are going to go on the back of the 4runner for backup lights.

When I bought those lights last week, they were $22 each, now they're $17! There's no way I could have made those for that price and that quality.

This weekend I'll finish up the axle, then move on to the light installation or maybe work on getting the Wave 6 catalytic heater plumbed in. Or maybe both since I'll have a 4 day weekend. This is all in preparation for snow camping at the grand canyon some time next year. Now that we have this camper, the wife is more agreeable to cold weather camping.

[Robinhood4x4]

I made a little more progress this 4 day weekend, but not as much as I thought I would. I had to help my brother work on his FJ-60, which is still sitting in my garage. By the way, changing motor mounts on that thing sucks.

In the last episode, we left off with the axle removed and the hangers shaved off. On saturday, I started welding on the new perches to the correct side of the axle for a flip, but as I got further into the welds the welder started acting up and giving me really porous beads, as if it weren't getting any gas. It was also not feeding the wire very smoothly. Finally, I figured out that the liner was bad which was causing too much friction which caused the wire at the feed to buckle and make spaghetti. One of the strands of spaghetti must have hit the knob which keeps the gun attached to the welder which in turn allowed the gun/hose to come loose, preventing the gas from reaching the end of the gun.

So on Monday, I headed to the welding store and got a new liner. It feeds much better now, better than it has in a few years. I no longer have to keep the hose perfectly straight and the beads are perfect once again (at least within my abilities).

Today, after measuring 3 times and welding once, I got the new hangers tacked to the frame. I think I have the axle to within 1/16" square, whereas I'm pretty sure it was originally off by about 1/4" from the factory. For the next few days I'm just going to keep it tacked while I mull over everything I did and make sure everything is correct, before welding it up completely. Oh, and Coleman did not weld up the original hangers like the instructions from Dexter say to. They welded only the sides of the hangers, while dexter says to weld around the front and back too.

http://antinode.smugmug.com/photos/i-qWnGWFb/0/XL/i-qWnGWFb-XL.jpg

Again I'm going blingy by painting the axle silver.
http://antinode.smugmug.com/photos/i-mdLcJvp/0/XL/i-mdLcJvp-XL.jpg

Here's the new perch welded on.
http://antinode.smugmug.com/photos/i-8LV39XJ/0/XL/i-8LV39XJ-XL.jpg

Stay tuned for the next episode.

[Robinhood4x4]

Sometimes I hate the fact that I have to do everything right, otherwise I could have had this done a long time ago. Here you can see where I beefed up the new U-bolt plates. They were originally flat like the old rusty ones, but as you can see, the old ones were all bent to hell. Well I couldn't have that, so I welded on some stiffeners. On top of that, I couldn't have rusty stuff under my camper so I also painted everything I could (you'll see this theme).
http://antinode.smugmug.com/photos/i-fHpNbFf/0/XL/i-fHpNbFf-XL.jpg

Before I welded the spring perches to the frame, I realized I had to pull out the wiring from the frame otherwise they'd get burnt to a crisp. That was a big pain the butt because some of the wires were kinda big and didn't want to be fished out. Plus, there was a plethora of those stupid crimp on wire splicers that had to be pulled out too. Did I mention I hate those things? No wiring of mine will have those because all they do is cut the strands of wire and introduce a spot for moisture to get in and cause corrosion. Those things went into the trash and out came the soldering iron. Every connection was soldered together, then 3-4 coats of liquid electrical tape were applied, then heat shrink tubing or electrical tape was used to cover it. Here's a shot of the axle under the trailer and some of the wiring hanging down for the brakes.
http://antinode.smugmug.com/photos/i-cCxWkVf/0/XL/i-cCxWkVf-XL.jpg

Fast forward to today, where I finally got to hook it up and take it for a spin! Here's how it sits:
http://antinode.smugmug.com/photos/i-dChMv2T/0/XL/i-dChMv2T-XL.jpg

http://antinode.smugmug.com/photos/i-3qP8kd2/0/XL/i-3qP8kd2-XL.jpg

http://antinode.smugmug.com/photos/i-zvTqXrn/0/XL/i-zvTqXrn-XL.jpg

It's a little nose low which is surprising because I even flipped over the ball on the hitch to raise it up some. Oh well, nothing a little lift won't fix. Here's what it looks like underneath:

http://antinode.smugmug.com/photos/i-xwCrpLn/0/XL/i-xwCrpLn-XL.jpg

http://antinode.smugmug.com/photos/i-4wpchNC/0/XL/i-4wpchNC-XL.jpg

http://antinode.smugmug.com/photos/i-PgQTVMZ/0/XL/i-PgQTVMZ-XL.jpg

In that last picture, it looks like I got a little too generous with the brake control. I was testing them out because before one of them wasn't working, so after this rewire, I wanted to heat them up a little to see if they were both working now. Looks like they are. By the way, these little 7" brakes don't do a whole lot. I can feel them slowing the truck a little, but they don't come anywhere close to locking up. The bigger tires don't help any either.

You can also see my wiring job. No exposed wires hanging down from crimp splices anymore. Everything zip tied, protected and strain relieved properly.

Here's my blingy wheels:
http://antinode.smugmug.com/photos/i-Q4VZRnZ/0/XL/i-Q4VZRnZ-XL.jpg

The step in height is now 25" so one of the next projects will be steps (the previous owner ripped the off before he did the axle flip).
http://antinode.smugmug.com/photos/i-NP49psw/0/XL/i-NP49psw-XL.jpg

Here's the tire clearance. Now that I look at it, I think I could have gotten the 26" LT tires to fit! Dammit. Oh well, if these things blow, off to craigslist they go.
http://antinode.smugmug.com/photos/i-LHKzXhh/0/XL/i-LHKzXhh-XL.jpg
http://antinode.smugmug.com/photos/i-Cqj8LFv/0/XL/i-Cqj8LFv-XL.jpg

Up next will be figuring out a way to mount the now larger spare tire under the tongue area since it won't fit in the normal spot and also extend the corner stabilizers. I'll make a run to the steel place tomorrow, hopefully.
http://antinode.smugmug.com/photos/i-ffzxtHW/0/XL/i-ffzxtHW-XL.jpg

So final stats:

24" Maxxis load range C tires
Suspension lift of 1.25"
Tire lift of 1.13"
Total lift about 2.4"
Distance from the ground to the bottom of the frame is 21.5"

Backing this thing up to my house tonight reminded me I really need backup lights. Anyway, this is only the beginning, lots more to come.

[paddlenbike]

Looks great Steve! And I am the same way with projects, it takes me forever because I get side-tracked with cleaning up everything else around what I'm working on.

I love that desert landscape too. :thumbup:

[Robinhood4x4]

This will be a short update. Made a run to the steel place and got some supplies to extend the stabilizers.

Cut the steel.
http://antinode.smugmug.com/photos/i-8sBv7tS/0/M/i-8sBv7tS-XL.jpg

Weld 'em up.
http://antinode.smugmug.com/photos/i-gktbqRH/0/M/i-gktbqRH-XL.jpg

Here's 3 of the 4 extenders done. I realized I needed the fourth square to use as a drilling template for the stabilizers on the camper, so that one will have to wait until later. You can also see the beginnings of a steel plate target I'm making for fun in the desert.
http://antinode.smugmug.com/photos/i-dw8bsmG/0/M/i-dw8bsmG-XL.jpg

That's all for now.

[Robinhood4x4]

Got done with the stabilizer extensions, but I fear the back ones are too long. I made them so that on level ground the stabs will be in the middle of their stroke, but it looks like they're too long to allow them to swing up and down.

http://antinode.smugmug.com/photos/i-4nD8nVX/0/L/i-4nD8nVX-L.jpg

[Crinale]

nice.. These stabilizers make me think of my project I need to work on... my off-road tent trailer project.

[Robinhood4x4]

Finishing up some loose ends with this phase of the project. Since the larger spare tire won't fit in the normal spare tire location I had to put it under the tongue. But since the nuts for the propane J hooks get screwed on from below, I had to come up with a different way of holding down the propane tank. Something else that was in the way of the spare tire was the propane regulator so that had to be moved too.

Starting with the J hook replacement, I bent up some flat stock in the shape of the original J hooks. Here, I used the vise and a big hammer to knock a 90 deg bend into the flat stock, then used another piece of flat stock to help create a nice sharp bend.
http://antinode.smugmug.com/photos/i-mxtVxTw/0/XL/i-mxtVxTw-XL.jpg

Here's the finished product.
http://antinode.smugmug.com/photos/i-CkQ8Mfp/0/XL/i-CkQ8Mfp-XL.jpg

Next came the mechanism to hold the spare tire to the tongue. Just a grade 5 bolt tack welded from the back to a piece of angle iron. The other pin is to help locate the bracket and the hitch pin is to hold the bracket to the wheel to make it easier to lift the tire up to the tongue.
http://antinode.smugmug.com/photos/i-rdjZQKS/0/XL/i-rdjZQKS-XL.jpg

Here's a picture of everything installed.
http://antinode.smugmug.com/photos/i-LRZw7Vg/0/XL/i-LRZw7Vg-XL.jpg

You can also see the new bracket I made which moves the propane regulator higher, out of the way of the tire. I never did like how low that thing hung down anyway. All the hitch pins through the bolts prevent the wingnuts from backing out.

Overall views
http://antinode.smugmug.com/photos/i-LKZV35m/0/XL/i-LKZV35m-XL.jpg
http://antinode.smugmug.com/photos/i-9t7mZDg/0/XL/i-9t7mZDg-XL.jpg

Now that I am truly done with the suspension phase, the next step will be to mount and wire the new LED flood lights.

[Marc P]

Can you come over and mod mine now?

[paddlenbike]

I like your modifications, they're all clean and well thought-out. A tent trailer is on my wish list. Heck, pulling a tent trailer around is how I justified the supercharger, so surely it would be prudent to get one, right?

[Robinhood4x4]

Thanks, I've been trying to up my game in the professionalism department because usually when things look professional they are done correctly and safely.

Of course, that also means everything takes 4 times as long. I spent almost my entire christmas vacation working on the trailer and didn't get anywhere near the things done that I wanted to.

Marc, sure thing, I'll be over just as soon as I get done with mine!

[paddlenbike]

Of course, that also means everything takes 4 times as long.


That is the story of my life.

[Robinhood4x4]

I've been promising lights, and lights you shall have!

Last year I ordered these LED lights from amazon, but back then they were on sale for $22 each.
http://www.amazon.com/gp/product/B008CSHRL2/ref=oh_details_o02_s00_i00?ie=UTF8&psc=1
18 watts, 1350 lumens each. I intended to use 2 for backup lights and 2 for work lights mounted to the roof.

First things first, wiring. Or in this case, fixing the original sucky wiring.

The main breaker is this thing with exposed terminals.
http://antinode.smugmug.com/photos/i-hvPggNg/0/L/i-hvPggNg-L.jpg

Seeing as how it still works, I didn't see the need in spending $20 for a new one, so I just wrapped it in heat string tubing. Much better.
http://antinode.smugmug.com/photos/i-KZJKGsv/0/L/i-KZJKGsv-L.jpg

As for the light wiring, I ran it through the frame, but at every connection I had to make, I waterproofed it by coating it in several coats of liquid electrical tape, then heat shrink tubed it.
http://antinode.smugmug.com/photos/i-pCg2WjW/0/L/i-pCg2WjW-L.jpg
http://antinode.smugmug.com/photos/i-fzT4Mcf/0/L/i-fzT4Mcf-L.jpg

For the reverse switch, I used a single pole, double throw switch which is wired to be On, Off, or Automatically switched on when I put the truck into reverse. I found a box at radio shack so I could waterproof all the connections and mount the switch in a protected area of the tongue
http://antinode.smugmug.com/photos/i-4L78c8K/0/L/i-4L78c8K-L.jpg

Here's one of the LED backup lights
http://antinode.smugmug.com/photos/i-hVJMg2w/0/L/i-hVJMg2w-L.jpg

[Robinhood4x4]

On to the roof lights. I decided to put the switch on the inside of the camper, just in case I wanted to turn on the lights when things go bump in the night outside.

This is the reason I hate those quick splice connectors. They cut through the wires which weaken the wire and could eventually break completely.
http://antinode.smugmug.com/photos/i-zTD5TzF/0/L/i-zTD5TzF-L.jpg

Properly soldered and self vulcanizing tape protected.
http://antinode.smugmug.com/photos/i-gGRQRcz/0/L/i-gGRQRcz-L.jpg

Here's the switch location, well within reach from outside the door.
http://antinode.smugmug.com/photos/i-B4SqzrX/0/L/i-B4SqzrX-L.jpg

To get the wiring up to the roof, I took a queue from the way Coleman did it and ran it through the seams of the canvas.
http://antinode.smugmug.com/photos/i-wDSXRH6/0/L/i-wDSXRH6-L.jpg
http://antinode.smugmug.com/photos/i-xDrBM2j/0/L/i-xDrBM2j-L.jpg

Here's how I mounted and sealed the lights to the roof.
http://antinode.smugmug.com/photos/i-DCSRxFp/0/L/i-DCSRxFp-L.jpg

With some scrap steel I had laying around, I made a backing plate to distribute the load of the nut
http://antinode.smugmug.com/photos/i-xfVRsSk/0/L/i-xfVRsSk-L.jpg

This is what it looks like on the inside
http://antinode.smugmug.com/photos/i-mmhjzmQ/0/L/i-mmhjzmQ-L.jpg

[Robinhood4x4]

And finally after all that work, it all pays off. Here's what the whole thing looks like.
http://antinode.smugmug.com/photos/i-29Vrb23/0/L/i-29Vrb23-L.jpg
http://antinode.smugmug.com/photos/i-P2dBNGm/0/L/i-P2dBNGm-L.jpg

I guess you all want to see what they look like at night.

Backup lights only.
http://antinode.smugmug.com/photos/i-sZ4xCjF/0/L/i-sZ4xCjF-L.jpg

Side lights only.
http://antinode.smugmug.com/photos/i-vvcqTJg/0/L/i-vvcqTJg-L.jpg

And both at the same time.
http://antinode.smugmug.com/photos/i-Rs2vh9h/0/L/i-Rs2vh9h-L.jpg

I'm pretty sure I heard the Hallelujah song playing when I flipped the switch, despite being in the middle of nowhere.

[Good Times]

lookin good there Steve! :)

[paddlenbike]

That's what I'm talking about...nice work Steve! There is nothing quite like good lighting when camping.

[4x4mike]

Looks good Steve.

So are these powered off the house batteries? With 4, or 2 and 2, do you have a junction block or relays?

[Robinhood4x4]

Nah, it's only got 1 deep cycle 12V battery, but yes, that's what's powering them. I installed a fuse block inside, but since they're only drawing 2.6 amps per pair, I didn't relay it. Instead, I fused them to 5 or 7.5 amps.

I'm not sure what the next mod will be yet, but still on the list are steps, an awning, 12V water pump, water heater, shocks, BAL leveler. Highest on the list are BAL leveler, which is a sort of jack that makes leveling easier, or steps. With almost 2 feet of step in height, my knees aren't going to last too long.