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-   -   Box truck to RV conversion. Crew Cab f450 (https://www.pirate4x4.com/forum/showthread.php?t=2472929)

DE Jeeper 02-13-2017 11:37 AM

Where did u get the windows? Need to replace the ones on the pete sleeper and was looking for something better then a single pane slider.

Java 02-13-2017 11:42 AM

Quote:

Originally Posted by DE Jeeper (Post 39856753)
Where did u get the windows? Need to replace the ones on the pete sleeper and was looking for something better then a single pane slider.

These guys, Boat Windows, Rv Windows | Motionwindows.Com, not cheap, but they would make them any size I wanted. Mine are all weird sizes.

Java 02-13-2017 11:43 AM

Starting on the gasket.
https://c1.staticflickr.com/1/756/32...c32700f7_b.jpg

all done
https://c1.staticflickr.com/1/267/31...bbde9e16_b.jpg
https://c1.staticflickr.com/1/675/32...99f4f8b3_b.jpg
https://c1.staticflickr.com/1/389/32...960a5ceb_b.jpg

Connected! just need to get the cab vents back in now.
https://c1.staticflickr.com/1/488/32...9d440cdb_b.jpg

GLTHFJ60 02-13-2017 02:03 PM

That is awesome.

watahyahknow 02-13-2017 03:46 PM

dont think you can prevent a coldbridge by insulating the inside of an aluminium profile , the cold will just conduct around the insulation through the metal
wat you can do is put foam tape or a thin sheet of polystyreen over the alu box section before putting on the inside walls
think if you want to do foam insulation inside the walls you could try to get 2 pack foam mix it realy fast and poor it in from the top between the inner and outer wall before it goes off (the expanding foam has enough forse to push the walls apart if you put too mush in there and it will gleu everything together so you whont be able to get the wall of without using excessive force ) or spray the whole inside with foam before shaving it mostly flat and then finish the inside walls
there you tube vids on those that i cant post for you at this moment due to forum politics

as for the cab off repairs : the overhead on the box prolly will make that tricky
maibe you can do a temporary hockey puck style bodylift kit so you have a little more room to work

Java 02-13-2017 03:48 PM

Quote:

Originally Posted by GLTHFJ60 (Post 39858353)
That is awesome.

Thanks!

Quote:

Originally Posted by watahyahknow (Post 39859521)
dont think you can prevent a coldbridge by insulating the inside of an aluminium profile , the cold will just conduct around the insulation through the metal
wat you can do is put foam tape or a thin sheet of polystyreen over the alu box section before putting on the inside walls
think if you want to do foam insulation inside the walls you could try to get 2 pack foam mix it realy fast and poor it in from the top between the inner and outer wall before it goes off (the expanding foam has enough forse to push the walls apart if you put too mush in there and it will gleu everything together so you whont be able to get the wall of without using excessive force ) or spray the whole inside with foam before shaving it mostly flat and then finish the inside walls
there you tube vids on those that i cant post for you at this moment due to forum politics

as for the cab off repairs : the overhead on the box prolly will make that tricky
maibe you can do a temporary hockey puck style bodylift kit so you have a little more room to work

Yeah I came up with the same conclusion. I left them alone. The ply strips have a slight R value, Im hoping thats enough. Its done now...

Java 02-13-2017 08:26 PM

Just about caught up on this thread now...

More big holes this weekend!
https://c1.staticflickr.com/1/601/31...fe29b31b_b.jpg

Window is just temped in, so the red tape is water proofing...
https://c1.staticflickr.com/1/524/32...817cc431_b.jpg

One next to the door too, hard to get a pic as its next to the garage.
https://c1.staticflickr.com/1/275/31...b97694af_b.jpg

Opens the inside up a bit!
https://c1.staticflickr.com/1/711/32...a6b3ab3d_b.jpg

Said good bye to my little trailer too :( That was my first big fab project.
https://c1.staticflickr.com/1/431/32...d823cc8c_b.jpg

Java 02-14-2017 10:34 AM

Long list before insulation.... Got a little more done last night.
https://c1.staticflickr.com/1/734/31...88bca945_b.jpg

Reinforced the large window. It was a little floppy, and I didn't wan the spray foam to hold it crooked. Used a piece of oak there.
https://c1.staticflickr.com/1/331/31...0408093c_b.jpg

List, done. Way more of a thrash than I was expecting. All the little stuff adds up...

https://c1.staticflickr.com/1/292/32...9f080e30_b.jpg

All the furring s done, all the wires wrapped, taped, glued in place.

https://c1.staticflickr.com/1/419/32...7e2d352a_b.jpg

https://c1.staticflickr.com/1/332/32...e33064b0_b.jpg

Importpower99 02-14-2017 11:09 AM

Nice work, subscribed so i can follow your progress

TireFryerSS 02-14-2017 11:10 AM

Quote:

Originally Posted by Java (Post 39824033)
Yeah I saw the receipt for the last long block... And he had a dealer buddy do it for cost.... Its got 4k on the reman thats in it now, so I am hoping it can go a few months before I need to do the deletes.

Know what went on yours?

Just found out last fri. #1 piston is dead. We think an injector tip blew off dumped fuel in and melted the piston. I have other weak injectors as well. So its getting pulled and rebuilt, new injectors and possibly a couple other goodies if its in the budget.

If you're not driving the truck too much since youre building the inside of the box, then you're okay. But you start loading it up and traveling, imo its just more premature damage to a good engine. Besides, you think it runs strong now, wait till all the bs is gone and its got a good tune in it :smokin:

Java 02-14-2017 11:13 AM

Quote:

Originally Posted by TireFryerSS (Post 39869937)
Just found out last fri. #1 piston is dead. We think an injector tip blew off dumped fuel in and melted the piston. I have other weak injectors as well. So its getting pulled and rebuilt, new injectors and possibly a couple other goodies if its in the budget.

If you're not driving the truck too much since youre building the inside of the box, then you're okay. But you start loading it up and traveling, imo its just more premature damage to a good engine. Besides, you think it runs strong now, wait till all the bs is gone and its got a good tune in it :smokin:

Thanks for checking back in!

It was the #8 that took a shit on this on of the previous engine. They thought the injector stuck. Rod ventilated the block.

Yeah tuners are just crazy money at the moment. I need to get it usable first. I will do it eventually but i need to come up with the $ first.

Sent from my SM-G900T using Tapatalk

MT4Runner 02-14-2017 02:06 PM

https://c1.staticflickr.com/1/711/32...a6b3ab3d_b.jpg

So much room for activities!

Java 02-14-2017 02:08 PM

Quote:

Originally Posted by MT4Runner (Post 39872361)

Haha sadly the kid gets that bed. But yeah its almost 4' tall.

a bit more....

Progress!

https://c1.staticflickr.com/1/345/32...904dee97_b.jpg

Now for the nasty part... Grinding it all flat.

https://c1.staticflickr.com/1/272/32...2ca5494c_b.jpg
https://c1.staticflickr.com/1/257/31...1523e787_b.jpg
https://c1.staticflickr.com/1/748/32...1aeae01d_b.jpg

GLTHFJ60 02-15-2017 08:04 AM

Quote:

Originally Posted by Java (Post 39872393)
Now for the nasty part... Grinding it all flat.

Damn! I bet it feels warmer already. Did you pay a company to do that or did you have the equipment to spray yourself?

Java 02-15-2017 08:13 AM

Quote:

Originally Posted by GLTHFJ60 (Post 39880953)
Damn! I bet it feels warmer already. Did you pay a company to do that or did you have the equipment to spray yourself?

Yeah 4" cup grinders.... Foam is too hard for anything else apparently.

I paid someone else to do it, and I am glad I did! Two guys in there for a couple hours grinding. I looked into the diy spray foam kits, it was $360 more to have someone else deal with it.

Java 02-15-2017 08:29 AM

Trying to catch this thread up.....

Annnnd Done!!!
https://c1.staticflickr.com/1/655/32...1e19b465_b.jpg

First panel up
https://c1.staticflickr.com/1/712/32...a067dbdb_b.jpg


Got another sheet on the wall last night. Aiming for one a night for the weekdays.
https://c1.staticflickr.com/1/385/32...1d1031bc_b.jpg

One more panel!
https://c1.staticflickr.com/1/484/31...8017afae_h.jpg


And the heater getting a bench run. Cant decide if I want to do a separate tank or pull from the main tank.
https://c1.staticflickr.com/9/8208/2...e8f6ca25_h.jpg

DE Jeeper 02-15-2017 12:06 PM

Go to the main tank. Done it this way on 2 different trucks. Just leave the tube 1" off the bottom.

Btw they have a priming sequence when i hook it up and it says u need a special harness but i made my own harness with a flasher relay and a standard relay harness.

Java 02-15-2017 12:13 PM

Quote:

Originally Posted by DE Jeeper (Post 39884721)
Go to the main tank. Done it this way on 2 different trucks. Just leave the tube 1" off the bottom.

Thanks for the input, Im kinda leaning the other way.... Id like to be able to run kerosene for higher altitudes if needed.

My thinking currently is to add a door (like used for basement storage on an RV etc) here

https://c1.staticflickr.com/4/3736/3...d0966b63_z.jpg

Its dead sapce there, and use a 6.5G boat tank in a cradle to fuel the heater. It gets 6.4 hours run time on 1G diesel, so it would be good for quite some time.

The other option is use a fuel cell there, but then I need access from the floor under the bed to fill. Not wild about that.

Early CJ tank many also be a good option for that spot.

http://cdn3.bigcommerce.com/s-si9xy/...0.1280.jpg?c=2

ben2go 02-15-2017 02:10 PM

Is there any way to insulate the floor from underneath? Maybe add solar board to the current floor and then install finished flooring on top. I'm not sure if 1-inch insulating foam would hold up to a finished floor on top of it, without wood support. That could get a bit time consuming to install, depending on your technique and speed.

Java 02-15-2017 02:12 PM

Quote:

Originally Posted by ben2go (Post 39886209)
Is there any way to insulate the floor from underneath? Maybe add solar board to the current floor and then install finished flooring on top. I'm not sure if 1-inch insulating foam would hold up to a finished floor on top of it, without wood support. That could get a bit time consuming to install, depending on your technique and speed.

Yes there is, the floor is 2x3 box tubing, I will eventually fit rigid foam in from below and sheet it with some sort of sheet metal. The floor will get a foam underlayment, but it doenst add my insulation, its a little though. Our past truck's floor wasnt insulated and frost on the floor sucks.

ben2go 02-15-2017 07:14 PM

Quote:

Originally Posted by Java (Post 39886225)
Yes there is, the floor is 2x3 box tubing, I will eventually fit rigid foam in from below and sheet it with some sort of sheet metal. The floor will get a foam underlayment, but it doenst add my insulation, its a little though. Our past truck's floor wasnt insulated and frost on the floor sucks.

Good deal.

Java 02-16-2017 10:41 AM

Cleaned the garage last night. I now have about about 6'x15' of usable space. Soon to be cabinet shop.... Also found out the cabover is still leaking.... Ugh. We got more than an inch of rain yesterday, once it drys out a bit Ill have to caulk it from the outside.

Knocked out the bed frame. Its dimensions kinda drive everything.
https://c1.staticflickr.com/3/2179/3...0f825e73_b.jpg
https://c1.staticflickr.com/4/3913/3...5c3af0ed_b.jpg

Java 02-16-2017 10:47 AM

Put about 70 miles on it Sunday, picked up the ceiling material. Its going to be knotty cedar T&G. Smells delicious! But it was smoking again, I think it may be leaking oil onto the exhaust, but it seems to do it randomly. I need to crawl under it again and see whats up.

Drivers Side wall done
https://c1.staticflickr.com/1/305/32...7a98b937_b.jpg

Ceiling started. Definitely a rustic cabin kinda look.
https://c1.staticflickr.com/1/306/32...0153de31_b.jpg

Test fit one of the lights Ill be using. I hope they are enough light! They are 3W 120lm each.
https://c1.staticflickr.com/1/263/32...672ba086_b.jpg

I was trying to get the two windows I have cut in yesterday as we are supposed to get 2" of rain today... I have had a cold coming on, and that sure didn't happen.....

I did get one in, and it was not fun. Turns out my walls are only 1 7/8" thick, not the 2" I planned on. And to make things worse the foam was a bit thin around the windows, this let the plywood bend in even more. So I have to cut a bunch of shims, and make things kinda the right thickness again. Then.... The wall has a big bow in it, vertically. So I couldn't just use the foam strip to install the window. Its glued in like a berklyer now. After getting that in I was spent. The good news is my new patterning bit for the router work great at cutting the holes.

Hole cut
https://c1.staticflickr.com/1/443/32...fdfd5c3b_b.jpg

Window in
https://c1.staticflickr.com/1/515/32...69f5ddf9_b.jpg

it got dark....
https://c1.staticflickr.com/1/537/32...c8caf2c4_b.jpg

My stairs came though, and they fit in the under body box! It was close, but they fit.
https://c1.staticflickr.com/1/598/32...1f87c580_b.jpg

I also picked up a battery combiner, its rated for 200A continuous, so it should be up to the task. Another CL score, $20!
https://c1.staticflickr.com/1/337/31...f4400221_b.jpg

gavan 02-16-2017 12:15 PM

Diesel/Kero isn't all that happy about sitting around for a long time. One of the big reasons to pull off the main tank. Put a bad tank with some algae in it and it's going to be much more of a mess after sitting . If nothing else make sure to add some algae killer over the summer.

Java 02-16-2017 12:19 PM

Quote:

Originally Posted by gavan (Post 39896929)
Diesel/Kero isn't all that happy about sitting around for a long time. One of the big reasons to pull off the main tank. Put a bad tank with some algae in it and it's going to be much more of a mess after sitting . If nothing else make sure to add some algae killer over the summer.

Yeah I put some conditioner in the last tank (one of the 911 winter ish ones, i dont remember exactly). I am still thinking two tanks as running kero in the heater will keep it from sooting up as quick at altitude.

hmmmmm Main tank pickup could be done with a switch for the second tank when needed. Ugh.

Dropping the tank doesnt sound like fun at the moment either.


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