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NJV6 ******
Age: 102 Zodiac: Joined: 20 Feb 2008 Posts: 1355 Location: New Zealand
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Posted: Sun Jun 28, 2015 9:16 Post subject: Pop top on steroids |
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I thought you guys might be interested in my latest project, a caravan camper pop top.
We had been thinking about it for a little while and roughly knew what we wanted, and this little gem came up for sale. We bought it sight unseen, and drove 1600km return to collect it off the Ferry. This was our first sighting
Once we got off the Ferry, time for a closer look. It is NZ made, a 1979 Liteweight Expander, basically a pop top with solid sides.
On the way home the name came to us, Miranda. Miranda the Expander.
Set up on the Lawn
My wife quickly get set too cleaning it and giving a bit of paint here and there, some pictures of the inside with the squabs out
I took a look underneath and saw a bit of the dreaded rust in the floor... so looked the other way and we then went away for the weekend to the beach
It looked a bit silly behind the wee Paj (had only had it behind big paj until now), and the rust was bothering me so it was time to get the grinder out. 1st take the wheels off, hard job to do with no wheel arches. So I made some
And some bigger wheels
To fit something like this, the floor had to be cut so out came the wheel arch and a bit of the floor
Couldn't get the wheel arch out of the otherside without stripping the entire sides of Miranda so just cut the back of it instead
Drilled out loads of pop rivets to pull the sides away to get at the rusty bits
This is the rust I was talking about
About now I decided to go all out , so I ordered some airbags from the states for suspension and decided the dump the rubber joints it currently used, it was just going to bob along the road otherwise. So with a heavier duty suspension the chassis was going to need laminated as it is only C section. 7 inches of travel will mean I can level Miranda on a non-flat camp site.
New chassis time
Then I fed the sheep
Lowering the chassis off the caravan
Rolling it out
Hover van
Now it was suspension time for chassis, Airbags need something to hold the axle in place, do I use some very light leaf springs for placement or use some suspension arms, I decided on the latter as it seemed like fun. I got some LandCruiser 80 suspension arms and used them as my lower links. About now I got some more suitable wheels and tyres to use, I was never going to use such fat alloys, i have some std hilux rims on 205x16's, may go a smaller tyre size or 3 yet, depending on final height.
and made the top link myself using the bushes from the original top landcruiser links
Caravan Flex
Ugly as anything but no one will see it! And it works! the axle sits nicely in place and does not rotate when lifting and lowering so the airbag remains stable. There is a bit of bracing to go on to it yet but I can't see much force going onto the top arm, maybe a little when braking but how effective are brakes going to be on a 800kg caravan anyway??
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Posted: Sun Jun 28, 2015 9:16 Post subject: Google Ads keep the POCUK free to join! |
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peteinchad LifeTime Member
Joined: 07 Jan 2013 Posts: 15079 Location: UK
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Posted: Sun Jun 28, 2015 10:12 Post subject: |
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That's an interesting project - and you get the best of both worlds - something easier to tow than a caravan but better than a tent for comfort.
It should last forever with all the work you've done. |
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Hugh Michael ****
Joined: 15 Mar 2005 Posts: 350 Location: Pembroke Dock, West Wales
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Posted: Sun Jun 28, 2015 14:59 Post subject: |
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Very enjoyable to watch how you planned and completed the work. Thanks for the post and the pics. |
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Davelincs **
Age: 67 Zodiac: Joined: 23 Jan 2015 Posts: 109 Location: Lincoln
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Posted: Mon Jun 29, 2015 6:56 Post subject: |
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Excellent work, keep us informed |
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MARKS600K1 LifeTime Member
Age: 53 Zodiac: Joined: 20 Nov 2007 Posts: 341 Location: BORDON HAMPSHIRE
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Posted: Mon Jun 29, 2015 13:23 Post subject: |
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Hello
Good job your doing there, thats a great name Miranda
Regards Mark |
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kalmac LifeTime Member
Age: 55 Zodiac: Joined: 26 Feb 2009 Posts: 969 Location: Norfolk depest darkest
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Posted: Mon Jun 29, 2015 23:20 Post subject: |
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good stuff, can't wait to see the next installment |
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NJV6 ******
Age: 102 Zodiac: Joined: 20 Feb 2008 Posts: 1355 Location: New Zealand
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Posted: Thu Jul 09, 2015 10:28 Post subject: |
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Must be time for an update,
So I had the airbags and wanted to get them mounted,
Upper chassis mount
And the lower mount on the axle
I then thought mounting it so far behind the axle may create a bit much leverage than id like. I had made them like that so I could mount them as low as possible and get the chassis to sit right down on the axle when not in motion to aid getting in and out.
Then farming got in the way again and I needed the woolshed for shearing so rolled the old chassis back under and took it for a drive to another shed
Back to it
Cut the old mounts i had just made (duh) in half and mounted airbags
And the the mig ran out of wire Grrr
Then fizzed them to the chassis
I have ordered a new water tank to go right behind the axle, as you can see from screenshot below, you can pretty much get anything you want! I am getting 47 litre, 2nd from top.
Then I started on the floor of Miranda, the reason all this started! So after lifting her off the chassis (again) I got a new rear sub frame made up then ran out of CO2 in the welder! Grrr
Here it is sticking out the side so I can weld the top of the joins.
Thats all for now |
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jimmybond *******
Age: 43 Zodiac: Joined: 05 May 2009 Posts: 4170 Location: bury st edmunds
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Posted: Wed Jul 22, 2015 9:17 Post subject: |
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Goog god you have way to much spare time on your hands lol.
I never understood the idea of a trailer tent etc.
My nieghbour went through a stage of wanting one.
bought one, used it once and said never ever again.
I dont know what bit he didnt enjoy.
that trailer tent stills sits in his garden.
is the idea for storage?
To me they feel cramped.
whats the idea of the air bags.
is it to lower it when on site? |
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NJV6 ******
Age: 102 Zodiac: Joined: 20 Feb 2008 Posts: 1355 Location: New Zealand
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Posted: Thu Jul 23, 2015 10:52 Post subject: |
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Quote: |
Goog god you have way to much spare time on your hands lol.
I never understood the idea of a trailer tent etc.
My nieghbour went through a stage of wanting one.
bought one, used it once and said never ever again.
I dont know what bit he didnt enjoy.
that trailer tent stills sits in his garden.
is the idea for storage?
To me they feel cramped.
whats the idea of the air bags.
is it to lower it when on site? |
Heck no, I don't have much time, More spare time would be great. Its a project, everyone needs one otherwise one day your old and think what have I done with my life...? Can't go back and do it again.
Yea we don't see many trailer tents around here, you see more tents and bikes and BBQ's etc all stacked into the boat rather than trailer tents. Is the idea for storage? I don't know, ask someone with a trailer tent!
Airbags is for a few things, level it on site, lower it on site, raise it when off road, and a far more compliant ride than leaf springs so save the insides rattling to pieces on potholed shingle roads. |
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jimmybond *******
Age: 43 Zodiac: Joined: 05 May 2009 Posts: 4170 Location: bury st edmunds
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Posted: Fri Jul 24, 2015 7:04 Post subject: |
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Nj46 clearly your age isnt right lol.
I thought on these sites its always funny to make yourself look alot younger lol.
clearly ive missed something!
I know what you mean about better ride.
I lent our caravan out to a friend.
it came back with the inner blind broken off kitchen window, the sunlight roof has blinds that cover both up.
both bust off hanging down.
must of drove like a a hole on rough roads.
put it this way ive had caravan from 1 year old and never had any of that. |
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NJV6 ******
Age: 102 Zodiac: Joined: 20 Feb 2008 Posts: 1355 Location: New Zealand
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Posted: Fri Aug 07, 2015 7:36 Post subject: |
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It has been a while since an update
So I got busy with the water tank frame, I wanted it removeable to be able to fully drain it for the winter frosts.
New mudguard frame so I could pop rivet exterior back into place nice and strong
Rear bumper and strengthening (not that it needs it!)
Finally got the Frame painted!
Stub axles welded on, pissed me off a bit as the engineer took 1mm too much off the stubs so they were hard to centre in the axle but hopefully it is close enough. Put the new chassis under the caravan
Made up some shock absorber mounts
Mounted shock absorber. In this pic you can also see how much of the floor I cut back to be able to fit larger wheels.
Cut the front of the drawbar off to make a mount for tow hitch
Hitch mount
And here is Miranda sitting under her own weight on 205R16 tyres with about 2 inches of air in the airbags, so it can go lower and another 5 inches higher
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NJV6 ******
Age: 102 Zodiac: Joined: 20 Feb 2008 Posts: 1355 Location: New Zealand
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Posted: Fri Nov 27, 2015 0:39 Post subject: |
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Update time!
Side access panel
Not content with all this,it was still eating away at my insides that there was still the rusty floor in the front to deal with as I had planned to do that next winter. But thought what the heck, out with the grinder. 1st a tidy up
Had to strip interior draws at the front and unscrew/drill out/beat out old stuff, what a job! But got there eventually
Done - happy now, no rust! Reassemble time
New mudguards
Brakes plumbed, airlines done
Rear stabilisers, obviously the wind down normal type were going to need a 4 inch block of wood to be effective so redesign
This is in its travel position, it sits about 2 inches proud of the roof and is going to be a kayak mount which will run the length of Miranda
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NJV6 ******
Age: 102 Zodiac: Joined: 20 Feb 2008 Posts: 1355 Location: New Zealand
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Posted: Fri Nov 27, 2015 0:53 Post subject: |
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I had wanted a new stronger top arm setup that holds the axle in place so made that
Installed
Started running wires for 12 volt system.
Ready for the 1st trip
O and got a bit sidetracked and bought a 2011 Gen 4 Pajero, build thread to follow! |
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NJV6 ******
Age: 102 Zodiac: Joined: 20 Feb 2008 Posts: 1355 Location: New Zealand
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Posted: Mon Jan 25, 2016 8:29 Post subject: |
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Not sure if anyone is following this but anyway,
So I got the water tank mounted and finished with new filler
Put the 12v switches in
Storage box and gas bottle
Spare wheel mounted
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skool *****
Joined: 24 Jun 2015 Posts: 764 Location: NOT IN THE EU !
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Posted: Mon Jan 25, 2016 8:42 Post subject: |
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defo a few of us look forward to updates on this ,, its all very ingenious and cool ,, well done
have to say youve changed it so much from what it originally was are you considering a colour change externally ? would look cool if it matched the tow truck etc unless youre keeping the vintage look ? |
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