Build 100 Series Pop-Top Camper Build

[JAntosch]

Been spending most of my free time on the BBQ smoking meats to support various functions, but finally got the drawers together and installed:

Still need to build out divider systems for them and get all the stowed in the right places, but progress is progress!

And a gratuitous rib photo:

 

[JAntosch]

Spent an hour or two yesterday getting the bluetti alternator charger installed:

Pretty straightforward overall, the supplied cables have a few feet of slack after running from the battery through the DS firewall grommet above the dead pedal. Added a 60a MRBF at the battery, and may swap the supplied DC breaker with a blue sea one at some point if the lower profile is needed. MC4 to XT60i adapter cable to charge up the ecoflow and we should be good to go!

I'll likely run the bluetti at a somewhat-conservative 30a (130a alternator for the '04), planning on 3x 100W panels on the roof to supplement power as the ecoflow has two XT60i inputs. A high-output (240a) alternator may not be a bad idea either....

 

[Live to Ski]

how did you manage your power cable to truck battery interface? pic pls

btw: i may be passing through slc on way to montana in january. if possible, i'd like to do a cursory look at your setup.

 

[JAntosch]

how did you manage your power cable to truck battery interface? pic pls

btw: i may be passing through slc on way to montana in january. if possible, i'd like to do a cursory look at your setup.

First time I've actually needed the under hood lighting, yellow arrows are the bluetti wires:

Maybe some additional tidying up once all the wiring is done, but the fuse box and terminals help keep things mostly accessible.

Terminals are from SDHQ (SDHQ Built Complete Billet Battery Terminal Kit - https://sdhqoffroad.com/products/sdhq-built-complete-billet-battery-terminal-kit?srsltid=AfmBOorlhWuV7ucokFJmO8wEn6Hs3HZQk_iEsOg3gvh3_xjjnHAYMHjI) and work with minimal modification. Some selective slicing of the covers, re-crimp the negative, and a little persuasive bending of the positive by the fusible link.

I'd be happy to show off whatever stage this is at if I'm around, be in touch when you're passing through!

 

[Live to Ski]

much appreciated. w/r pos terminal, just bought a one of those square crimpping tools for wire ends. hoping that it, in combination w post multi terminal thingy, will keep the wiring organized. one thing i hate is electrical trouble shooting

 

[JAntosch]

much appreciated. w/r pos terminal, just bought a one of those square crimpping tools for wire ends. hoping that it, in combination w post multi terminal thingy, will keep the wiring organized. one thing i hate is electrical trouble shooting

Should do the trick! I've been using a die crimper (https://www.amazon.com/dp/B00MVE48Z6?tag=ihco-20) for lugs with good results so far. Another reason I went the ecoflow route, modular with minimal custom wiring and mostly plug and play!

 

[JAntosch]

Got the insert panels cut, routed, and installed. Still figuring out the best option for some kitchen storage next to the grey water can, maybe a bin and bungee cords for retention?

Wires for the rear outlets, lights and diesel heater are in, still need to tidy up the cable routing but it's all functional. Waiting on the pull-out cutting board, more hex-ply, and aluminum extrusions to get started on the bench and roof rack!

 

[Live to Ski]

any plans to recove the center storage between the front seats? may ease in cabin movement.

 

[JAntosch]

any plans to recove the center storage between the front seats? may ease in cabin movement.

hmm, not currently but may indeed be helpful for moving around! I'll have to see how easy it is to go from cargo area to front seats with the platform up, have a safe from massive metal shop in the center console that I'm quite fond of

 

[JAntosch]

Spent a few days in the central Utah desert wandering around and checking out petroglyphs as a shakedown run for the build thus far. Very happy with the results, some further iteration needed here and there, and a few oversights but no glaring issues. Minimal rattles all around, likely due to how gear got loaded. A bit cozy hanging out inside for two adults and two 45 lb dogs, but ample room once we got things figured out.

The highlights from my notes:
-Suspension feels great full loaded, will still need some shock adjustment once fully built.
-Water system works nearly perfectly, sink drains well on level ground and grey water jerry is easy to remove and dump.
-Kitchen setup is solid, used the drawers for random storage but need to build dividers to store the cook gear.
-Current paper towel holder is a huge miss and will need to be re-done. The mounting point is solid, but the holder itself is too flimsy for rough off-road driving and cannot stand up to an excited dog in the morning.
-Storage next to the grey water tank will be prioritized, I'll try a small basket/tote with bungee cords to store extra paper towels, sanitizer, trash bags, soap, etc.
-A down comforter is far superior to a double-wide sleeping bag in the pop top.
-Easy to move between front seats and cargo area with the platform raised, so no plans to remove the center console. (for reference I'm 5'9" and my wife is 5'3")
-So much sand got tracked in. Easy enough to vacuum out when we got home, but a sand mat and a small broom/dustpan are requirements for future trips.
-Cooking inside when it's ~25F out generates a lot of condensation that freezes and rains on you in the morning as soon as the sun hits. Further diesel heater optimization may eliminate condensation (likely also from breathing, not having pop top windows open, etc.).
-Diesel heater (2kW) needs to be run on full blast to heat the extra interior space to ~65F when it's in the mid 20s outside. Made some modifications to shorten the hoses which helped, but need to make a mount for it to shorten hoses even further and/or get some silicone tubing to improve efficiency. I'm planning on filling the gaps under the rear platform with closed cell foam to improve insulation, may look into window insulation as well.
-Bluetti charger set at 27V worked well to recharge the Ecoflow over ~2 hours of driving (~30% consumption after cooking, running the diesel heater for ~17 hrs, coffee, and charging various devices)
-Some type of back rest will be needed for the bench section, currently brainstorming how best to integrate this in a space efficient manner.
-Coffee setup is perfect.

A few photos:
Diesel heater after some modifications

Old dog still loves desert time

Morning coffee goodness

Rad barrier canyon style pictographs

 

[JAntosch]

Finally back at it after finals and holidays and weather and general laziness and waiting on components. Trying to get a bunch of stuff knocked out before the next semester starts.

Realized the extra width of the drawer fronts would interfere with plans to use the pull out table/cutting board to make a bed platform in the cargo space, pulled them apart and cut down the panels so they'll sit flush with the kitchen frame. Still need to figure out some sort of drawer stop. Made dividers for the deeper drawer, waiting on some more foam to finish up the shallower one. Dividers are coroplast with 2mm closed cell foam, joined with bobby pins, kind of a DIY/custom fit TrekPak and much cheaper although you have to put in the arts and crafts time.

Pulled the kitchen to pull the rear platform to add some 10mm sound deadener/insulation, very happy with the additional road noise reduction so far! Added anchor points for the cargo section of the passenger side bench and should be installed shortly.

And while everything was out, pulled the interior plastic to access the headliner and bolt up some l-track mounts to hang the diesel heater as shorter hose runs should equal better efficiency. Wish I had though to have this welded on when the pop-top was built, but the tie-down backing plate and plenty of butyl tape should make these quite solid. I considered mounting these on the emu wing, but decided the ~30 pounds of heater and diesel would put too much strain on the sikaflex holding the emu wing on.

 

[Live to Ski]

Looking good JAntosch.

I mentioned my desire to inspect your rig as an inspiration for my rig

As threatened, as it stands this second, I will be passing through slc sometime thurs 1/22 into fri 1/23. what's your best guess as to timing within those 2 days. I will be visiting dental floss (read big sky, montana) friends prior to those dates. Look to be only 5+-hrs north of slc.

that's all the news that is not fit to print

 

[JAntosch]

Looking good JAntosch.

I mentioned my desire to inspect your rig as an inspiration for my rig

As threatened, as it stands this second, I will be passing through slc sometime thurs 1/22 into fri 1/23. what's your best guess as to timing within those 2 days. I will be visiting dental floss (read big sky, montana) friends prior to those dates. Look to be only 5+-hrs north of slc.

that's all the news that is not fit to print

Thanks!
Later afternoon/early evening should work well either day, be in touch as plans evolve and change!

 

[Live to Ski]

10-4, roger roger, sounds good

 

[Live to Ski]

as my last post mentions: ".... second...."

just got wind that my big sky friend has a blown acl

consequently, my trip (including the slc portion) is postponed to late summer/early fall. Hopefully you will still be in slc at that time. can you confirm/deny?

 

[Pullupthendown]

Awesome build. Is the Campteq something you had installed or did yourself?

 

[TheIcemanCometh]

If you are looking for an easy/clean way to hook your dometic faucet into your scepter can, you might like this: Scepter/MCI Water Can Cap - https://shop.iggycorp.com/products/scepter-mci-water-can-cap

I've been using one for a couple years and love it! (I have no affiliation with that company)

Nice idea. One question that I would ask the person making them is if the cap is printed using a food safe plastic. Also the clunk is aluminum, being in water I would rather have SS or brass.

I think for the connection I would contact Scepter about getting one of the fittings used on their water can dispenser and run the tubbing directly through (with a reducer). One could still have a quick disconnect.

Very nice build. You have given me some ideas for my fridge base which is located in place of the second row PAX seat.

 

[JAntosch]

as my last post mentions: ".... second...."

just got wind that my big sky friend has a blown acl

consequently, my trip (including the slc portion) is postponed to late summer/early fall. Hopefully you will still be in slc at that time. can you confirm/deny?

Woof, nothing kills a ski trip like a blown acl . Hope they heal up quick!

I will indeed still be in Salt Lake late summer/early fall, be in touch when plans start to take shape!

 

[JAntosch]

Awesome build. Is the Campteq something you had installed or did yourself?

Thanks! I had the Campteq installed, adds to the cost a bit but I don't have the space/equipment/desire to attempt myself.

 

[JAntosch]

Nice idea. One question that I would ask the person making them is if the cap is printed using a food safe plastic. Also the clunk is aluminum, being in water I would rather have SS or brass.

I think for the connection I would contact Scepter about getting one of the fittings used on their water can dispenser and run the tubbing directly through (with a reducer). One could still have a quick disconnect.

Very nice build. You have given me some ideas for my fridge base which is located in place of the second row PAX seat.

All good points on the cap, and I like the idea of modifying the scepter fitting! I'll likely revisit when we start taking longer trips, but this iteration should work ok for our current 4-5 day outings.

PM sent about second row platform!