Welding

Next task is to fabricate the rear access door and my fold out 'annex'. Since there is so little room inside the camper I decided it needed an easily erected, covered area at the rear for cooking, toilet, shower and the like.

I had done a little arc welding many years ago and now find the most common type of home welder is a MIG (metal inert gas) welder. Luckily these have reduced in cost and a suitable unit for a home workshop is not a big investment.

Thankfully people are generous enough to produce welding tutorial videos and put them on You Tube. I found this video particularly useful.

I used 25mm x 25mm hollow square 3.2mm mild steel for the frames and bracing. I did quite a few practice welds before beginning on the real stuff. MIG welding is a lot easier than ARC welding, especially on thinner materials, but it still takes practice. I am hooked on welding now.

My welding 'practice'

LED lights

I decided to change the old rear lights for brighter LED lights. Funny how the simplest thing can become a major issue.

Firstly, turn indicators in Australia must have a feature (to meet Australian standards) that lets the driver know when a 'bulb' has blown, usually this is a rapid flash speed. New Zealand doesn't have this requirement but most relays have this function anyway.

Because an LED draws so little power, the relay thinks the bulb is blown and flashes rapidly. One solution is to add a resistor to each light to increase current draw but this seems to defeat the purpose of LEDs which is to reduce power usage. The other option is to replace the flasher relay with one designed for LEDs. Before I knew it the LED light costs were mounting up. Of course there are a number of different types of relay units some have two pins, some three and there are three or four different layouts of the pins. In the end I made some short leads with a spade connector on each end and connected it this way. All in all, quite a few hours spent over this small issue.

The new relay also does not make a sound; not a big issue but does take a bit of getting used to.

First steps

Being a Fire appliance, it had some equipment that was not required. It was fitted with a mains electric (110v) heater to warm engine coolant and oil so the vehicle was ready for immediate full throttle use. All this had to come out.

I have removed the wiring and switches for the beacon and siren which was between the front seats. Eventually I will build a custom centre console.

 going...

 gone.

The gate switch disconnects all electrics so as to ensure the battery is not flat when the vehicle is required. I have replaced this with a new design battery isolator switch which is much safer.

Nest step is to replace rear lights so it can get a 'warrant of fitness' (wof) to be allowed to drive on the road.

Design

Think First Class rail sleeper rather than motorhome and you may imagine something closer to the end result.

The truck really decided the design. Although the 'crew cab' seems a negative at first, it does provide lots of storage space.

Most importantly, it had to be possible to sleep across the vehicle. This was the first measurement I made and it checked out... just. Bunks, with the top bunk folding up away, seemed the most space efficient and useful way of sleeping.

Second importantly, the beds must be comfortable. You can put up with many things after a good nights rest but lose sleep night after night and the smallest problem can become a big issue. Beds don't need to be large but they must be comfortable. Ridges or hollows where cushions meet or hard buttons can be sure to cause an uncomfortable nights tossing and turning.

Trying to explain an idea in your head to someone else isn't easy to get right. A solid model, to scale, is a great way to make sure all bits work together and 'she who must be obeyed' has the same concept in her head.

Background

We've had a few trips to the South Island of New Zealand in a variety of vehicles from 6 berth motorhome to motorbike. We have taken the motorhome on to unsealed/dirt/metaled roads but it is not a pleasant experience.

If you can get off the seal there is another whole island to explore and you'll probably have it to yourself.

Most 4WD campers are not 'off road' vehicles. They have no clearance and poor suspension and a myriad other limitations. We needed a real off road vehicle...cheap.

Toyota Land Cruiser model FJ62V. Low mileage, well looked after, perfect.

With the PTO pump and deck removed we have

The Adventure Machine

Why?  We want to explore the 90% of New Zealand that you can't get to with a motorhome.

What?  A converted 4WD Fire truck

this is the how...