Framing the Bed

To frame up the bed I first had to make and install the Birch panels on the bedroom walls.

I used the original panels as a template but for some reason they didn't line up perfectly. It doesn't matter though, the entire bottom half will be hidden by the bed and the top half will be covered with trim.

Next I built the base for the bed.

Then I built the rest of the framing. I used a 2x6 to make the curved section.

It rained the entire afternoon which made things go really slow. I still have a little bit of framing left to do on the nightstand section on the right. I will use two pieces of 3/4" plywood on top of the framing. One piece will be at the very back, the other larger piece will be hinged so it can swing up for storage access.

Finishing up the floor

I finished the floor today. It went down pretty easily.

As you can see in the last picture the floor does not go all the way to the back. The very back is where the bed will be so there is no need to run the floor all the way back.

After finishing the floor I worked on putting up the wall panels in the back bedroom.

The reason the electrical comes out here is that the bed will run from the opposite wall to about 12" from this wall, the rest of the space will be taken up a built-in footboard/night stand. The dual voltage electrical panel will be in a hidden, recessed panel in here.

Tomorrow I will finish installing the remaining three wall panels and then frame up the bed / nightstand.

Wiring and Insulation

I spent last weekend on the wiring and insulation.

I'm running all new 14 gauge romex for the 110v and 14 gauge automotive wire for the 12v. The outlets and two kitchen florescent lights are 110v and the rest of the lighting is 12v.

The panel I will be using is the PD4560, it is a combination 110v panel and 12v panel with a built-in power inverter to power the 12v side. It will be mounted in the back in a panel next to the bed. You can see where all the wiring goes too in the picture above.

With all the wiring done I started on the insulation. I got about 1/3 of the way done. To install the insulation I first sprayed the area with rubberized undercoating and then immediately put the insulation in place. This has a two-fold benefit. First it sound-proofs the shell a little bit and second it helps to hold the insulation in place.

Hopefully I can finish the insulation this weekend and start on the new paneling!

Front Windows

I installed one of the front side windows today. Let me tell you it was the biggest pain in the ass!! It took hours to get it installed.

NOT looking forward to doing the other ones.

I also installed the 7-way trailer plug.

Tomorrow I'll work on the other front side window.

Tail Lights

I got the tail lights installed yesterday.

One thing I want to mention that is very important. Be VERY careful how tight you install the screws for the trim piece and what you use to install them with. I used my little Ridgid impact to install the screws, the combination of the impact and torquing the screw down too much caused the lens to shatter. At $75 a piece for originals that's a very costly mistake.

I also began working on installing the front wrap around windows. I clamped the piece of lexan directly to the camper and traced out the window shape on to it. Then I cut along the line with my jig saw,  then I used a scribe set at 1/8" to make a new mark because the gasket takes up that much all the way around. Then I cut along the new line. I intalled the gasket in the window opening to get the proper length for it.

I will install the window today when I have a second set of hands for help.

Trailer lights

Yesterday I worked on the trailer lights, they were in really bad shape but I have both original tail lights and three out of the four original KD-540 running lights.

As you can see the bases are completely rusted out. There are reproduction bases for the KD-540 but I cant afford them right now so I decided to make my own.

First I had to find some light sockets that would work, I got these for $2 each.

Then I traced the pattern from the trim piece.

Then I put the cutout up to the side of the camper to locate the holes I needed to drill into it.

Then I rivited the bulb socket to the cutout.

Not as elegant as the reproductions but it works.

Next I screwed the new bases to the camper using stainless screws then attached the lenses.

Once I find some flathead stainless screws I will replace the phillips head ones.

I ran all new trailer wiring to all the lights. I didn't get a chance to finish installing the Bargman no. 2 tail lights but I did get them and the new center license plate stop light wired up.

I also finished up on the tongue. First I sanded it down with a wire wheel.

Then I sprayed it with a rust inhibiting sandable primer.

Then I sprayed it with a high strength enamel gloss black paint.

Rear Taillight

I got some new stainless bolts and test fitted the new license plate bracket/stoplight.

I'm hoping to get a lot of work done on the camper this weekend.