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Freightliner camper shell

Discussion in 'Open Bar!' started by Robbyrockett2, Apr 28, 2018.


  1. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    So heres my most recent little project.
    Heres how it began life
    AB025A.jpg
    And here it is finished , well almost, I added a set of fiberglass folding stairs after this
    AA_0000A.jpg

    I'll post up some some process pics when I get back home.
    The idea was to make this pickup tool bed into a camper shell to fit the freightliner.
    With a couple provisions for the fact that the new version of this truck has sort of a stepside bed which makes the rails narrower. The customer plans on getting the new version so I built the bottom for that.

    Basically I did a one off molding process and replaced everything below that black trim.
    Deleted the side hatches, added windows and a vent.
    Painted it and put on all new trim

    Attached Files:

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  2. huskystafford

    huskystafford Mac-Valve Maestro!

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    I am always surprised how much talent you can find on OAF -.-
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  3. SiRoxx

    SiRoxx Party Boy UK Style Very Likeable!

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    Looks good Buddy. That’s an interesting project.


    Sent from my iPhone using Tapatalk
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  4. Jurien72

    Jurien72 Have Airbrush - Will Travel!

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    Wow thats a pretty sweet camper!
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  5. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    So knowing Id be adding 7.5" in height overall I cut the floor out before I ever took it off the truck. It turned out to be waterlogged and over an inch thick (300-400lbs) anyhow so it got ditched.
    AB020A.jpg

    and loaded it onto a rolling cart, that be a yenko camaro beside it waiting for parts.
    AB015A.jpg

    all this junk will be cut out when the outside is complete.
    AB011A.jpg

    First order of business was to get some templates on to make the new shape
    The backside structure of the hatches will be cut off later, at this point the customer had not informed me he wanted to delete them and add windows. The plan is to fill the space between the templates with styrofoam blocks and shape them, using the templates as a guide.
    Soon to find out, I cant get big blocks of foam in NC nearly as cheap as I used in FL, at least not in time for this project.
    AB013A.jpg
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  6. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    The corners, with their compound curves still needed to be foam. 2" pink insulfoam and expanding foam to the rescue.
    AB009A.jpg

    Sides got the slat treatment, and then polywall. This leaves a lot of bodywork to be done after layup and i dont really like to do it this way but it fit the bill for this project.
    I dont like to drywall mud it before layup like some do with this method. even the quick set stuff retains moisture for a long time and interferes with the resin cure.
    AB007A.jpg

    Attached Files:

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  7. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    AB004A.jpg
    Then carved and sanded the corners
    Another camaro in the back there
    Last edited: Apr 28, 2018
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  8. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    Ready to layup.
    AA028.jpg
    And now we're cooking with glass
    Also ive cut out the internal structure of the doors and screwed the skins in place to get glass tabs
    AA025.jpg
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  9. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    AA019.jpg

    Now I've got the first layer and a half of glass on. Normally I fishcale (grind and taper) a larger area for the joint but I didnt have the space under the side hatch, so I settled for about three inches outside and then laid in a layer at the joint on the inside, equaling the normal 6 inches or so I would use.
    AA021.jpg

    And its time to go upside down
    AA017.jpg
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  10. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    I layed in a 1/2" plywood floor, which got braced by 2x6.
    The floor was glassed in sections, then joined in strips, a big flat panel is basically impossible to glass at once. It will pull and warp all over the place.
    Then i glassed down and joined the floor to the sides in a stairstep pattern so seams dont meet and the glass layers are the same thickness (more or less)
    The whole project was a little sloppy as the customer kept reminding me it wasnt one of these nice cars and it was just a work truck.
    AA012.jpg

    On its side now, I put bedliner on the bottom and tested some different white paints for a match to the gelcoat per request ( which I knew wasnt gonna happen and id have to paint it all anyhow)
    AA003.jpg
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  11. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    Now I cut out the original structure and pulled all the mold plug material out from the inside.
    That box on the floor is for clearance for the 5th wheel and the customer intends to mount a table to it.
    He didnt want to remove the fifth wheel because it would change the way he would have to register the vehicle.
    Inside is now 83 inches across
    The 2x6 running across serves a support for the stair mounts/ battery box storage for the solar panels that will be installed on the roof.
    AA022A.jpg AA011A.jpg
    And I start to fill the deepest waves in the body
    AA019A.jpg
    Last edited: Apr 29, 2018
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  12. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    Filled and blended to a reasonable point
    AA016A.jpg

    Being a one-off and lacking a foam plug some areas of filler were thicker than I was happy with so it got a layer of 6oz cloth squeegied tightly over the whole thing
    AA017A.jpg

    Then sprayed with nasons 2k high build primer/ I'd planned polyester like I do most glass because it builds like crazy and is just awesome on top of any one-off glass but when it came time to prime I had the nasons on hand so I just went with it. It still managed to hide the Cloth texture of the 6oz. reasonably well without much print through. The roof just got a quick sanding/ he didnt care much about the roof and gel coat gets along with most paint pretty well
    AA010A.jpg
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  13. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    The first coat revealed some holidays I'd missed in the primer on one side so I had to fix them with some spot putty before 2nd and third coats
    This was a 2k single stage sprayed with a graco finex 1.4
    AA015A.jpg

    Windows , powered fan vent and trim installed, bottom side rails and floor interior sprayed with SEM bedliner. Interior walls and ceiling were sprayed with latex mixed with micro balloons ( provides some minimal sound and thermal insulation)
    I'll try and get some interior shots posted sometime.
    AA007A.jpg
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  14. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    And here I am breaking all the forklift safety rules during install.
    AA005A.jpg
  15. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    Couple of closeups.
    0428181106b.jpg 0428181106.jpg 0428181058.jpg 0428181101.jpg
    And the stairs. I repurposed the pneumatic cylinders to take about 10lbs off the 20lb weight of the stairs. The gate latch secures them, the bungee just keep the rattle down from the gate latch.
    0428181057.jpg
  16. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    And the finished pic is at the top
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  17. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    Thanks guys!
  18. huskystafford

    huskystafford Mac-Valve Maestro!

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    Crazy good work, not to mention you made a bunch of photos and described to us what you did. Thx for sharing this with us.
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  19. Robbyrockett2

    Robbyrockett2 Air-Valve Autobot!

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    Thanks, nothing to do with airbrushing, so im just glad that some people are interested.
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  20. huskystafford

    huskystafford Mac-Valve Maestro!

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    Threads like this one, motivate me to push my self more and further, so no need to thank me. I need to thank you :)

    edit: and I just realized I am not ninja anymore :( Ninja is better then maestro. lol

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