Dave's Four Wheel Camper Flatbed Project: Zephyrus

[Dave]

During the last big trip we compiled a list of things we needed in the camper as well as things we didn't need. I also made a list of things I wanted to modify.

High on that list was the "house battery box". FWC got about 90% of it right but I saw some wasted space there that I wanted in play as a place to put wine glasses, cups and the assorted cell phone cable or random things you want easy access to while inside but dont want it cluttering the countertops or buried in a bin somewhere. Here's how it turned out!

First I added some structure above the batteries, ensuring that there was room for maintenance as well as no pinched or chafed cables. Just enough room!

Positive connections are all carefully covered with wiggle room.

Next, the view from the inside. A bit of quick paint so it doesn't look like crap. The floor is removable via 4 screws if batteries need to be inspected or tended to.

Plenty of room for things, but it still seemed unfinished. Previously this was just an access hatch to the batteries, but all that wasted space drove me nuts!

The next step for me was clear, it needed TrekPak.

Much better now!

 

[Dave]

Another issue I discovered during the last big trip was what I consider to be a structural flaw in the seating on the flatbed Hawk.

The L shaped extrusions that support the cushions/seat in one key area were prone to fail - screws into 1/2 inch plywood were not going to hold up long term, and I'd already noticed them giving way. So, I addressed this design oversight by adding some "legs" to transfer the weight to the floor. The fire extinguisher and exterior light switches are on the other side of this panel in the doorway.

Here's some upper inside detail shots, the aluminum L shaped extrusion was supporting the seat/bed cushion. This area gets sat on ALOT so reinforcing it was mandatory for me. YMMV.

Washers were used as spacers to ensure my screws didn't pierce the exterior lamination on these panels. Here you can really see the extrusion that was supposed to bear the weight of the dinette seating.

While I was at it, I added a divider to this underfloor compartment so that the girls have separate bins to "move into" when they add all their clothes and gear for a trip. This is easily accessed by removing one seat cushion.

Here in this overhead view you can also clearly see the surfaces that support the seat cushions when they are in place, now reinforced and easily ready to support 300 lbs.

Overkill? Yes, it's what I do

Inside details of where the divider attaches to the exterior wall.

Having space for the girls to put their things away (no gear bombs inside the camper!) and not mix them up will reduce stress on trips and save time.

 

[Redline]

Nice update and customization Dave.

 

[Dave]

Thanks James

 

[buckwilk]

Amazing build, really fun to watch and learn. Thanks

 

[Dave]

Amazing build, really fun to watch and learn. Thanks

Thanks!

 

[Chris Griggers]

Wish I had all the extra space above the batteries! Our has maybe 3 inches above them.

 

[live2travel photography]

Dave yet another amazing thread. After going through the truck build I had a lot of new ideas, and now I have even more on my build sheet after reading this thread. One question; why did you go with the propane over diesel Truma Combi? After reading where you had to fill up the propane tanks several times during your road trip it seems like it would have been nice to have the heater just pulling fuel from the diesel tank? Thanks in advance for your reasoning!

 

[Dave]

Dave yet another amazing thread. After going through the truck build I had a lot of new ideas, and now I have even more on my build sheet after reading this thread. One question; why did you go with the propane over diesel Truma Combi? After reading where you had to fill up the propane tanks several times during your road trip it seems like it would have been nice to have the heater just pulling fuel from the diesel tank? Thanks in advance for your reasoning!

No special reason - I was just the first one that FWC built with a Truma.

On that note, I love the Truma. It's been flawless.

 

[live2travel photography]

No special reason - I was just the first one that FWC built with a Truma.

On that note, I love the Truma. It's been flawless.

After reading even more on them I really want to get one when I build my Habitat. Having a single unit for water and heat would be amazing as I wont have nearly as much room as a flatbed Hawk. I'll have to really ponder the diesel vs propane idea now

 

[CON KSO]

Man - this just got me really excited! I just ordered a flatbed Hawk from Mario at AT but I decided to go with Marc at XPCamper to build the flatbed for me.

Quick questions:

1. Do all of the new flatbeds - like mine - come with the Truma unit now?

2. Ballpark figure: How long does it take the Truma to get 6 gallons to a comfortable shower temp? And - I think you said you just leave the Truma on while your driving - is that correct?

Thanks - your rig looks great, super functional and capable. It's just making me even more crazy to get mine completed.

 

[Dave]

Man - this just got me really excited! I just ordered a flatbed Hawk from Mario at AT but I decided to go with Marc at XPCamper to build the flatbed for me.

Quick questions:

1. Do all of the new flatbeds - like mine - come with the Truma unit now?

2. Ballpark figure: How long does it take the Truma to get 6 gallons to a comfortable shower temp? And - I think you said you just leave the Truma on while your driving - is that correct?

Thanks - your rig looks great, super functional and capable. It's just making me even more crazy to get mine completed.

Thank you. As far as I know, mine is the only one with the Truma to date. I’m sure you can specify it.

The Truma is a combo unit so if your heater is on, your water is getting hot too by conduction. It gets hot pretty quick, I’d say from cold start to “shower ready” easily within 30 minutes (depending on outside temps of course).

 

[kmacafee]

Dave -- those mods are great. It also illustrates that, as good as FWC's are, sometimes their build quality and attention to detail is lacking. For example, on my 2012 Eagle, the hinges on the panels used to access the turnbuckles pulled out. When I went to fix it, I was amazed by how small the screws they used were. In fact, they were smaller than anything I could find at the big box hardware store and I upgraded their size obviously.

It's not limited to FWC either. I did some work on a $100K+ Sportsmobile and was really disappointed in their build quality as well. Screws were missing their intended targets, some nicking electrical wires, etc.

Thanks for sharing these.

 

[Dave]

Dave -- those mods are great. It also illustrates that, as good as FWC's are, sometimes their build quality and attention to detail is lacking. For example, on my 2012 Eagle, the hinges on the panels used to access the turnbuckles pulled out. When I went to fix it, I was amazed by how small the screws they used were. In fact, they were smaller than anything I could find at the big box hardware store and I upgraded their size obviously.

It's not limited to FWC either. I did some work on a $100K+ Sportsmobile and was really disappointed in their build quality as well. Screws were missing their intended targets, some nicking electrical wires, etc.

Thanks for sharing these.

I've never owned anything that couldn't benefit from a few mods

 

[ArkansasDon]

Dave that is a sweet rig. Tastefully done & is clean looking w\o all the bling stuff attach to it.

 

[Dave]

Dave that is a sweet rig. Tastefully done & is clean looking w\o all the bling stuff attach to it.

Thank you

 

[Dave]

I've had a ton of questions lately about costs and what it took to build this out to date. Here's some updated numbers for reference based on current prices circa December 2017:

Here's some numbers:

2016 Ram 2500 4x4 Cummins Turbo Diesel, Big Horn Package, MSRP $58,500
2016 FWC Hawk Flatbed, fully optioned, MSRP $37,000
AT Overland custom aluminum flatbed tray w/Fiberthane storage boxes, $10,000
Miscellaneous Camper Modifications, $1,000

*Truck and camper with aluminum flatbed conversion = $106,500

Icon Vehicle Dynamics Stage 4 suspension (2.5 inch lift), Airlift 5000 airbags, coil spacers etc, $5,000
BFG AT/KO2 37's with TPMS, 17 inch steel wheels, mount/balance etc from America's Tire, $2,500
Rigid lighting, $3,000
White Knuckle Offroad Products Rock Sliders (HD), $1200
Buckstop "Boss" bumper, $2,800
sPod 4x4 "SE" with touchscreen, $750
Warn 16.5 ti winch, synthetic line, accessories, $3,000
AEV snorkel (for safety), $420
OEM Ram HD fender flares, $300
Nitro Gear 4.30 gears, $1,500
ARB Air Locker, rear, $1,000
ARB On-Board High Performance 12 Volt Twin Air Compressor (CKMTA12), $545.00
ARB manifold and ARB 1 gallon aluminum air tank, $250
Maxtrax with lockable mounting, $600
AT can carriers and Scepter water/diesel cans, $500
HD OEM folding/heated trailering mirrors, $400
(Lots of other little bits I'm not listing as well)

*Modifications and Accessories = $23,765

Grand total of major items comprising this build to date:

$129,765

(labor costs are probably an additional $8K)

 

[WashingtonTaco]

Thats almost what my first house cost!!!!!

 

[Dave]

Thats almost what my first house cost!!!!!

Ssshhhhh!

She’ll hear you...

 

[ArkansasDon]

it all adds up fast doesn't it