The "Pimp My Pop-Up" thread! Now with more welds! (Warning! Photo heavy!)

[Rednecktek]

So I started with preliminary designs and ideas in another thread, and then wouldn't ya know it a 1998 Coleman Pop-Up camper suddenly showed up in my driveway!



According to the seller everything works!
Except that the propane is disconnected...
The battery was half hooked up backwards and ratchet strapped to the tongue as there was no battery tray or box...
And the furnace didn't work...
No power was getting to the house battery...
The rubber lip around the roof fell off...
The water pump isn't pumping...
The pulleys and gears were running their factory grease...
The second propane tank was missing...

But other than that!

At least all the canvas and windows and upholstery is in good condition.

So I got my pieces on order and started playing with it. Had to take the heater to a specialist for a week to get it running and replace the regulator. There is no power going to the house battery to charge it even though the house battery DOES power the lights and furnace... Odd... And then some weirdo shows up with some steel and a welder! Man, just LOOK at those krappy welds! I oughta fire whoever put that thing together! ?



I still gotta engineer how I'm going to support this assembly and where I can attach more steel to the frame to reach it, but that's for the next few weeks when it stops raining (hopefully).

I messed up ONE of my penetrations to the breaker and distribution box in the Apache case, so now I gotta drill a whole new set of holes, but that's coming along nicely. I just got the parts today (I think) to build the pre-charge circuit that is going to the left of the main breaker. Hopefully the 250a Class-T fuse will mount in the current holder, right now it's just a 160a I'm using for sizing.



I special ordered a pair of JBD 200a 4s Heated BMS's from the JBD store... come to find out today after stuffing ALL THE KRAP into those Noco Group-31 boxes that there is NO HEATER PLUG!!!! Gods damnit!!! So now I'm going to have to get external thermostats involved to get the heating pad in the bottom to work because there is NO WAY in HELL that I'm taking those batteries apart now that I've got everything tucked in there!



Fortunately I have thermostats on hand (I think) that I can re-route power to externally to get the 12w heating pad (the red plaid thing in the bottom of the boxes) to kick on and off. So far I'm 0 for 4 on BMS's that supposedly have heating functions.

Since the converter box is right at the ass end of the camper and I'm going to be mounting that new tray to the back bumper, I figure the new Ionic 2Kw 12v Low Freq AIO inverter can go right under the seat along with a DIN box with AC and DC breakers for distribution...



Hopefully... This thing is HUGE!!!!

In order to avoid having to run a single wire all the way forward to the emergency brake system, I decided I'd just mount a small AGM battery up there dedicated to the brakes. I grabbed a 35Ah AGM, a cheapie 10a PWM controller, and a 25w panel to throw up front. That should (in theory) never need to be touched once it's mounted.



The SAE plug hanging out there goes to the little 25w mono panel I gotta figure out how to mount where it's not in the way of the nose wheel crank.

So yeah, gotta keep myself busy!! On the To-Do list still (in no particular order):

Mount 4x 200w 10BB Bi-facial panels and a 4-port combiner box to the roof and run cable down to the Apache for the PV disconnect breaker
Build a brake battery mount
Flip the axel over
Install the electric lift motor and controller
Mount the battery tray back aft
Figure out the water pump situation
Test the propane water heater (requires working pump)
Replace the absorption fridge with a compressor fridge
Install a 2nd AC circuit to feed the fridge and coffee pot
Install the fold out awning
Replace the lights with LED's
Mount USB charging ports inside
Cut and stitch in Reflectix window insulation
Trace and separate DC circuits, it seems everything is on a single 15a fuse currently
Install a power port to power a portable water pump so I can fill the water tank from the river
Replace the factory matresses
Ceiling projector?
LED light strips outside?
Wire in the new inverter and AC/DC circuit breaker box
Get pots/pans/dishes/stores/linens/etc
Bluetooth speaker system?
Insert Third Thing Here
Catch Phrase!

So yeah, nothing really to do! ?

 

[Daddy Tanuki]

So I started with preliminary designs and ideas in another thread, and then wouldn't ya know it a 1998 Coleman Pop-Up camper suddenly showed up in my driveway!

View attachment 190538

According to the seller everything works!
Except that the propane is disconnected...
The battery was half hooked up backwards and ratchet strapped to the tongue as there was no battery tray or box...
And the furnace didn't work...
No power was getting to the house battery...
The rubber lip around the roof fell off...
The water pump isn't pumping...
The pulleys and gears were running their factory grease...
The second propane tank was missing...

But other than that!

At least all the canvas and windows and upholstery is in good condition.

So I got my pieces on order and started playing with it. Had to take the heater to a specialist for a week to get it running and replace the regulator. There is no power going to the house battery to charge it even though the house battery DOES power the lights and furnace... Odd... And then some weirdo shows up with some steel and a welder! Man, just LOOK at those krappy welds! I oughta fire whoever put that thing together! ?

View attachment 190539 View attachment 190540

I still gotta engineer how I'm going to support this assembly and where I can attach more steel to the frame to reach it, but that's for the next few weeks when it stops raining (hopefully).

I messed up ONE of my penetrations to the breaker and distribution box in the Apache case, so now I gotta drill a whole new set of holes, but that's coming along nicely. I just got the parts today (I think) to build the pre-charge circuit that is going to the left of the main breaker. Hopefully the 250a Class-T fuse will mount in the current holder, right now it's just a 160a I'm using for sizing.

View attachment 190543

I special ordered a pair of JBD 200a 4s Heated BMS's from the JBD store... come to find out today after stuffing ALL THE KRAP into those Noco Group-31 boxes that there is NO HEATER PLUG!!!! Gods damnit!!! So now I'm going to have to get external thermostats involved to get the heating pad in the bottom to work because there is NO WAY in HELL that I'm taking those batteries apart now that I've got everything tucked in there!

View attachment 190548 View attachment 190549

Fortunately I have thermostats on hand (I think) that I can re-route power to externally to get the 12w heating pad (the red plaid thing in the bottom of the boxes) to kick on and off. So far I'm 0 for 4 on BMS's that supposedly have heating functions.

Since the converter box is right at the ass end of the camper and I'm going to be mounting that new tray to the back bumper, I figure the new Ionic 2Kw 12v Low Freq AIO inverter can go right under the seat along with a DIN box with AC and DC breakers for distribution...

View attachment 190554 View attachment 190555

Hopefully... This thing is HUGE!!!!

In order to avoid having to run a single wire all the way forward to the emergency brake system, I decided I'd just mount a small AGM battery up there dedicated to the brakes. I grabbed a 35Ah AGM, a cheapie 10a PWM controller, and a 25w panel to throw up front. That should (in theory) never need to be touched once it's mounted.

View attachment 190557 View attachment 190558

The SAE plug hanging out there goes to the little 25w mono panel I gotta figure out how to mount where it's not in the way of the nose wheel crank.

So yeah, gotta keep myself busy!! On the To-Do list still (in no particular order):

Mount 4x 200w 10BB Bi-facial panels and a 4-port combiner box to the roof and run cable down to the Apache for the PV disconnect breaker
Build a brake battery mount
Flip the axel over
Install the electric lift motor and controller
Mount the battery tray back aft
Figure out the water pump situation
Test the propane water heater (requires working pump)
Replace the absorption fridge with a compressor fridge
Install a 2nd AC circuit to feed the fridge and coffee pot
Install the fold out awning
Replace the lights with LED's
Mount USB charging ports inside
Cut and stitch in Reflectix window insulation
Trace and separate DC circuits, it seems everything is on a single 15a fuse currently
Install a power port to power a portable water pump so I can fill the water tank from the river
Replace the factory matresses
Ceiling projector?
LED light strips outside?
Wire in the new inverter and AC/DC circuit breaker box
Get pots/pans/dishes/stores/linens/etc
Bluetooth speaker system?
Insert Third Thing Here
Catch Phrase!

So yeah, nothing really to do! ?

Jeeze you sound like me about 15 years ago when I bought my first camper

 

[400bird]

According to the seller everything works!
Except that the propane is disconnected...
The battery was half hooked up backwards and ratchet strapped to the tongue as there was no battery tray or box...
And the furnace didn't work...
No power was getting to the house battery...
The rubber lip around the roof fell off...
The water pump isn't pumping...
The pulleys and gears were running their factory grease...
The second propane tank was missing...

But other than that!

Sounds like an average craigslist/marketplace seller!

Insert Third Thing Here

I think that one is about 147th on the list, you just don't know it yet.
Seems like a good project

 

[scrubjaysnest]

Our 2002 the converter never did charge the battery. Swapped batteries on the tongue once a week in 2010 when we did the Alaska trip. In Montana got smart and swapped interior lights to led and battery swaps went to once a month.
Never had a heater so used a small Mr. Heater. Oh, and the axle was bent. 3 sets of tires for 20 k miles.

 

[Mattb4]

I like the insulated battery pass through terminals you used on your battery box builds. Could you tell me where you got them?

Nice job on your build!

 

[Rednecktek]

I like the insulated battery pass through terminals you used on your battery box builds. Could you tell me where you got them?

Nice job on your build!

I got them from Amazon. The large 3/8" terminals for those battery banks and for the smaller 1/4" terminals for my smaller batteries.

I think that one is about 147th on the list, you just don't know it yet.

I'm hoping I run out of issues and can make that #139. ?

 

[Rednecktek]

Sooo... quick wire question y'all;



Benefit of paying almost 250% more for "Welding Wire" vs just getting THHN?

 

[time2roll]

Enjoy that camper. Had same year similar pop-up I bought when it was only two years old and had been used once. Great times for five years.
The battery situation was miserable for me back then. As shown there should be no issues.

 

[Mattb4]

Sooo... quick wire question y'all;



Benefit of paying almost 250% more for "Welding Wire" vs just getting THHN?

Looking at Temco for 4/0 welding cable I am seeing around $6/ft.

 

[Rednecktek]

Looking at Temco for 4/0 welding cable I am seeing around $6/ft.

Thanks!

 

[Rednecktek]

Aaahhh, good old "Waiting For Parts".... I had to go to my old tried & true digital thermostats to get the heating on the batteries going and I was sure I had 2 in my bins...

Then I remembered I had to use one when my JKs at the camp both died.

Well krap, gotta wait until tomorrow for another thermostat. At least one is done. I gotta get some zip ties in there to clean it up but it's programmed and charging so I'll do that later this week.

I built my precharge box and started drilling out the new fuse box. Everything should clear now but I gotta wait until the new Class-T gets here today as the measurements are smaller than my place holder so I gotta scoot stuff around.




Once that's in place it'll be drill the last few penetration holes and a little cable management.

Motor lift and parts along with the new awning are supposed to show up today too. Hopefully the weather plays nicely for a few more hours.

 

[Rednecktek]

Success!!! With the use of some 1/2" copper pipe, a vise, a hammer, and a drill I managed to make a bus bar to reach the new weird fuse. The box is about as wired as I can get it until the thiccc cable comes in and I actually start mounting everything to the tail end.





For those of you who worry, there are 3 bus bars there held together by a piece of heat shrink so it better be PLENTY of copper. ?

I was hoping to grind off the nose wheel and replace it today but every time I try the sky turns black. At least I got the first 2 coats of bed liner on the 2 battery trays. Yes, that durned welder showed up again! ?

No love on the motor kit yet, delayed AGAIN so maybe Thursday if I'm lucky.

 

[Rednecktek]

Today's update isn't too exciting. I finalized the batteries and set the heaters to start at 1c and end at 8c, insulated the probes a bit, and got some zip ties involved in wrangling the wires inside.



The 4/0 isn't going to work, 3/0 is the largest thing I can get through those glands. At 350a rating that's still overkill for a 2kw inverter. Sadly my crimpers only go up to 1/0 and I can't slide the lug in there, so waiting on tools instead of parts for a change!

Other than that I spent some quality time on the rubber roof lip with a wire toothbrush. This thing has been stuck back on before judging by the 2 types of goop in there. I'm thinking Sikaflex when it's dry and clean enough to put it back on.

Rain all week is preventing me from lopping off and replacing the nose wheel, mounting the brake battery, installing the lift motor kit, or building a strong back assembly for the battery tray.

 

[Checkthisout]

Where's the trailer going for it's first trip?

 

[JRH]

According to the seller “everything works!”….

YOU KNOW , that’s one of the 3 biggest lies in in the world… I won’t mention the other two.

J.

 

[Rednecktek]

Where's the trailer going for it's first trip?

Most likely the airstrip in Greenwater where we do our family camping trips, but it's some 8+ months away until I'm back off a boat and everything is finished.

According to the seller “everything works!”….

YOU KNOW , that’s one of the 3 biggest lies in in the world… I won’t mention the other two.

J.

I'm from the Gubment and I'm here to help.

Of course I'll respect you in the morning.

 

[JRH]

Most likely the airstrip in Greenwater where we do our family camping trips, but it's some 8+ months away until I'm back off a boat and everything is finished.


I'm from the Gubment and I'm here to help.

Of course I'll respect you in the morning.

Those are good but not what I meant…I learned them 40 years ago…a simpler world… by now I’m sure there is 10 of em…

 

[Daddy Tanuki]

Today's update isn't too exciting. I finalized the batteries and set the heaters to start at 1c and end at 8c, insulated the probes a bit, and got some zip ties involved in wrangling the wires inside.

View attachment 191289

The 4/0 isn't going to work, 3/0 is the largest thing I can get through those glands. At 350a rating that's still overkill for a 2kw inverter. Sadly my crimpers only go up to 1/0 and I can't slide the lug in there, so waiting on tools instead of parts for a change!

Other than that I spent some quality time on the rubber roof lip with a wire toothbrush. This thing has been stuck back on before judging by the 2 types of goop in there. I'm thinking Sikaflex when it's dry and clean enough to put it back on.

Rain all week is preventing me from lopping off and replacing the nose wheel, mounting the brake battery, installing the lift motor kit, or building a strong back assembly for the battery tray.

you are the first person I have met from the US that knows about Sikaflex! that stuff is the cats friggin meow!

 

[JRH]

you are the first person I have met from the US that knows about Sikaflex! that stuff is the cats friggin meow!

I used in in the 80s on boats… good stuff.

 

[Rednecktek]

I used in in the 80s on boats… good stuff.

That's where I learned about it too. Unfortunately, much like Coroseal, it became really hard to find because it worked too well.

 

[Checkthisout]

you are the first person I have met from the US that knows about Sikaflex! that stuff is the cats friggin meow!

Generally used to fill expansion joints

 

[Daddy Tanuki]

Generally used to fill expansion joints

they have 3 different formulas they sell here in japan. two are construction grade, the last one is specific for glueing in windshields of vehicles. its some bad ass stuff.

 

[Daddy Tanuki]

That's where I learned about it too. Unfortunately, much like Coroseal, it became really hard to find because it worked too well.

i can get it any time you want it... just let me know you want one of the construction grades or the one for glueing the windshields in with? they also have the activator and the adhesive promoter for it in liquid brush on form.

 

[Rednecktek]

Tongue is done! Built a tray for the brake batery and welded it inside the A of the tongue. Replaced the top spin (that hit the propne tank!!) with a double wheel side spin wheel. Screwed down the solar panel on the other side of the A and it folds vertical if needed for access and driving.



I just got back from picking up the steel to move the back bumper aft another foot or so to support the battery bussel. My new wire should be here next week and I'll be about ready to move inside. The motor kit seems to be missing pieces and the directions for it don't seem to line up with what's in my hands so I gotta ping the company about that.

The rubber lip is about the last outside thing I'll be able to get too once my Sikaflex arrives and I get some good weather to clean the surfaces.

Who knows, the panels might even get mounted before I ship, but Ii'm not holding my breath on that. The 1" T track is hard to find locally.

 

[Rednecktek]

Good productive day today despite massive slowdowns like rain and my welder exploding. After 5 or 6 years, dozens of projects, 4 or 5 camp trips, and miles and miles of wire run through it, it finally went Pop, Pop, POP SMOKE! this morning. Sigh....

So I picked up a new one, only $150 (which is a LOT less than the $469 I bought mine for) and picked up the CORRECT size steel and once it dried out this afternoon I finally got around to marking and drilling and welding to get the rear bumper moved back about 16" from the original placement.



After a couple shopping trips for nuts & bolts, I got everything snugged down and test fit. Nice!



Adding all that steel and batteries to the rear lightened the tongue up a bit, so now it's 175lb on the nose wheel. Since the water tank is up there that'll add another 160lb to the nose which is heavy to lift but not as bad as it was before I started this project.

Hopefully Sunday it'll be dry enough to take the battery tray off, add in some more welds to the strong-backs underneath, cut & weld in some cover plates over the open box tube, and get some paint on things. Once the paint is on I can run some wire to a couple lights on the ends of the new bumper just to make it more visible. Sadly, it's looking like rain, rain, and more rain all week.

I'm hoping I don't need to add another strong-back under the passenger side of the battery tray. It doesn't wiggle much with the battery on there and doing a bounce test, but it's also right over where the lift motor is getting mounted sooo... we'll see once the motor is installed.