Desert Turtle - M1010 Build

Finished fulling gutting the box and cleaning up some. Started taping floor plan and mocking up fridge, heater, water heater and stove. I think my layout ideas are going to work.

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First official camper item installed. Wife and I got the awning installed. Installation went well and had it done in about an hour and a half. Very happy that is done. Much rather store it on the truck than in the garage. LOL

I think I will fab up a tree branch guard at the front edge, so to not get snagged on anything.

Getting it test fitted with the two outer brackets.
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Installed with all three brackets
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Will that awning free-stand without legs?

It has mounts (which I haven't installed yet) that allow you to put the legs back to the vehicle, so nothing touches the ground but the legs are needed for support. It is not 100% free standing like some of the 180* and 270* awnings out there.
 
It has mounts (which I haven't installed yet) that allow you to put the legs back to the vehicle, so nothing touches the ground but the legs are needed for support. It is not 100% free standing like some of the 180* and 270* awnings out there.

I figured, but thought I'd ask. Thanks for the clarification.
 
Well this past weekend I decided I wanted to see if I could make corner pieces for the box. If these would come out good, I would do a full roof raise as it will keep thing clean looking. To do this I had to make a "die" for my press brake, so I could form aluminum sheet. Some flat stock and a piece of tubing welded together and I had my die. These actually came out great and fit the corner curve of the box perfectly. I will end up welding them to the box.

Built the die
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.125" thick aluminum plate and making bend in press brake
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End results
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Looks great, Mike! Did you have to anneal the sheet? That's always my concern with Aluminum since I don't keep acetylene on hand and propane doesn't do enough heat for big sheets.
 
Looks great, Mike! Did you have to anneal the sheet? That's always my concern with Aluminum since I don't keep acetylene on hand and propane doesn't do enough heat for big sheets.

I did not. I used 5052 sheet, which can bend easier without cracking. Since it wasn't a tight radius, seems to be no issues looking the pieces over. Definitely would not use 6061 unless you anneal it.
 
Well I finally got time and committed to my direction. The roof raise has begun. Used an air chisel and cut the rivets (technically Huckbolts) off from the backside and they popped off like butter. Then used my floor jack and a piece of tubing to start lifting the roof off the side and the sealant let go easily. I think it was about 30 minutes to get the roof free. Then I made some temp spacers out of aluminum and lifted the roof. This all went well and the roof is fairly light, just bulky. Now a couple of mistakes were made with the temp panels and total height. My plan is to raise the roof 8". For whatever reason in my head, I cut my spacers at 8" but did not account for the overlap I needed on the sides. This resulted in the roof being 7" higher. Okay, no big deal. I measured the floor to roof beam and have 72" total, up from the original 65". No worries, wife and I can stand comfortably but really wouldn't want it lower. Happiness was short lived when I realized I still need to account for the flooring, which will add about an 1". That puts me at 71" inside height. Luckily this is all temp so I can adjust before I start the side wall framing and have panels cut to fill.

Air chisel did all the easy work and lots of open holes around the top.

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Just getting the roof popped off

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Temp panels installed

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Had a very busy, tiring but productive weekend. Lots of cutting, fitting and welding done on the roof raise project. I have the two side walls and rear wall framework completed. Need to do the front wall and then skin everything. So far happy how things are turning out. Some progress pics. BTW, I have to say I am really liking my new welder. It's a Harbor Freight Titanium 170 with their Titanium 150 spool gun. I have it dedicated to doing aluminum only. I have two other MIG's for steel welding.

Cut, fit and weld, lot of this. This Fireball Tools welding square is awesome for doing this type of work.

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Test fitting and getting ready to add top rail

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Top rail added and roof locked down with temp screws. View from outside too. I was lining them up to match the existing wall rivet pattern.

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Building rear wall framework and installed

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Are you going to create some windows up there? Looks like a possibility. Always enjoy seeing the work you are doing on this rig.
 
Are you going to create some windows up there? Looks like a possibility. Always enjoy seeing the work you are doing on this rig.

I thought about it. As cool as it would be, adds to cost and complication. Not likely but not completely ruled out.
 
Small update, got the 4 corner pieces welded on. Still need to do some finish grinding and clean up. Overall fit well, not perfect but should do fine. Next up is skinning the outside. Need to get the side done with a step flange so I will have to farm that work out, since I don't have a bead roller nor space to keep one.

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Finally got my sheet skins for the project. Had a local fab guy do a step flange on the two pieces for the sides. Worked on getting the first side done. Overall very happy how it is turning out but I am beat. It was very hot and getting up and down off my ladder/scaffolding was a pain. My wife was a great help as it was too big to hold and clamp down myself. She also drilled the panel from the inside, while I held a block tight on the outside. Used Silaflex and rivets. Roof is just sitting on there as I still need to do the other three sides before I can permanently seal and rivet down the roof panel. Starting to look like it's going to work out.

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Another long and tiring day but got the rear and the passenger side sheets installed. Very happy how this is coming out. Now I have the hardest wall to finish, the front. There is not much access to the middle area due to the cab and the A/C unit. Not looking forward to doing this one.

Rear
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Pass side
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Productive day. Got the last skin done on the box. Actually was easy as I slid the roof back about 2' and was able to use ladders inside to reach over. Got the corners sealed up and riveted. Last part to do is seal and rivet the roof. Getting close.

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