Rebuilding a 1999 Jayco Pop Up

[Hornd]

Found this for $350 - Son of my Fathers Lifelong Friend. I think it was more of a Project than he Anticipated.

I think the pictures answer a lot of Questions.

Very Fun & Rewarding Project, but taking way more Hours than I anticipated.

Had intentions of Insulating the Floor but had no way to Make it Flush so Skipped.

Will be adding a Diesel Heater this Fall & 2 Solar Panels on Roof with Charge Controller and Batterie(s)

May add Load Bars on Top to Carry 2 Kayaks that weigh 40 Pounds Each

Weight of Camper is 1100 Pound Empty. GVWR 1800 Pounds - Tows Nicely without Auxiliary Brakes.

 

[Hornd]

Removed all 4 Cabinets in Interior including the Propane Line and Electrical and Water Line - 1 Hour

Removed the Floor. Found Rot at Front Right Corner and Along Rear. Water and Sun Takes these Trailers Out. The Sun Cooks the Sealant then water gets in unknowingly and Rots out the Frame.

Removed 9/16" OSB Flooring and Replaced with 3/4" Treated Plywood (2 Sheets) $106 from Menards - Took 10 Hours

Screwed down with Tech-Screws

Had to Lift off walls using Floor Jack as Walls sit on Floor.

 

[Hornd]

Trailer had Light Surface Rust.

Hit all that was Accessible with Wire Wheel in Angle Grinder & Drill

Sprayed with Fluid Film ($40 Amazon) and Astro Sprayer ($30 Amazon)

 

[Hornd]

Removed Rear Bed - 5 Bolts

Remove and Replace Aluminum Skin and Framing.

Glued Extra piece of Flooring to Skin with Liquid Nails.

Replaced Framing with 2x4 Cut down to 1" Depth.

Took 1 Night after work till 10:30PM

 

[Hornd]

Glued 18x18 Commercial Carpet Tiles to Floor - Took about 4 Hours

Made Stainless Covers for where Gas Line Goes thru Floor.

Redid Fender Boxes using Originals as Templates.

Added Toolbox, Fire Extinguisher, and First Aid Kit - Rodent Repellent from Amazon.

 

[Hornd]

Boys Discovered the Built in Bathroom

Took it on a Trip to Traverse City

 

[Hornd]

Table doubles as a Bed when Legs are Folded.
Old table was 3/4" MDF - Warped & Edging Gone - sorry I forgot to get Before Pic.
Use Old Table as Template to cut 1/2" Plywood.

• Bought Prefinished Oak Flooring Remnant Boards at thrift store for $8.
• Found Centerline then Glued Boards 2 at a time using Liquid Nails.
• Iron on Oak Edge Banding around Perimeter.
• Used Stainless Screw on Velcro Strap (Amazon) to hold Legs Folded.
• Used Stainless Screws to Mount Folding Legs.

New Table is Both Pretty & Functional (No Bend) with Low Cost but Takes Time.

 

[Hornd]

Next up will be Adding 8 Foot Awning from Napa.
Familiar with this unit as it is Mounted on our Land Cruiser 80.
It's Nice Quality.

Price $140.70 delivered to Store.

Original Awning Was Difficult to Put away in the Cold to it being Vinyl and from 1999.
Storage Bag starting to Rip on Both Ends. It served well.

 

[Hornd]

Salvaged an Oak Pallet from work and Planed the Boards and Glued them up to make Top.
Rest is Scrap.
Still needs some Inner Corner and Outer Corner Trim.
Finish is Tung Oil so it can be Reworked Easily. Still Smells.
Stick on Pockets are from Amazon $15

*Read on FB that someone said that Microwave was best Modification they made so I found a Small one to Try.
Time for Poverty Nachos and Micro Popcorn and Heating up Leftovers.

 

[Hornd]

Loving the Balkamp Napa Awning - $140.70 - Details above.
Awning is Rip-stop Cordura and Very easy to Stow Unlike the Stiff Vinyl.

**Need a Step Stool or Milk Crate to Stow it.
**Disregard the Stove I ran into next to door and busted to Pieces - Rebuild time.

Add the $10 Amazon LEDs ~8Ft. Batteries lasted at least 3 Nights- Still Going - Use Velcro Strap for Battery Box.
LEDs are Dim enough to not Ruin the Ambiance.

Plastic Tightner on Guideline can be Replaced with Tautline Hitch (best camping knot btw)