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Old 02-01-2018, 01:11 PM   #301
MTCK
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Re: My K5 Blazer Story.

Interesting.... I have to condition my rubber roof in the spring. Not looking forward to that annual bit of maintenance.
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Old 02-02-2018, 01:00 AM   #302
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Re: My K5 Blazer Story.

I've been a little lax in updating. Not as much on the truck done, but camper work has been happening. So here's an update from a few more weekends worth of work completed. Without further delay, here goes...

The roof needed resealed and all the screws replaced. The old vent was wasted and got a fresh one from one of my tech's tearing apart another RV.
Work on the roof by Rob Zulian, on Flickr

The rack got pulled for better access and the entire roof cleaned of old garbage with a wire wheel, scrubbed and dried. Then coated.
Work on the roof by Rob Zulian, on Flickr

Work on the roof by Rob Zulian, on Flickr

After seeing the piss poor setup for sealing the camper to the truck when we first loaded it (all they use is foam camper tape) I knew it had to be done in a better way. So we had to get the truck back under the camper to get solid measurements for an idea I had.
21902 by Rob Zulian, on Flickr

You can see the problem here. The cab has a natural channel built in for the stock seals to go to for the top. Without the fiberglass top in place the channel is a natural path for the drainage to go right to the bedrail and then inside.
IMG_20171210_120141109 by Rob Zulian, on Flickr

I sourced another K5 top with help from a member on CK5.com who chopped it down to the first few inches for me. After getting the measurements needed with the camper and K5 together we screwed down a section of landscape edging for a straight edge.
IMG_20171210_124559809 by Rob Zulian, on Flickr

Let the cutting commence..Measure twice cut once right?
21905 by Rob Zulian, on Flickr

This is Shane, Johns brother doing the inside surgery with the wheel of death.
IMG_20171210_125935445 by Rob Zulian, on Flickr

The final product. Just enough to fill the gap.
IMG_20171210_131000050_HDR by Rob Zulian, on Flickr

Here's the part mocked in place. Fit like a glove.
IMG_20171210_131820652_HDR by Rob Zulian, on Flickr

IMG_20171210_131800746 by Rob Zulian, on Flickr

With the top section in place, holes were added from the stock top holes back through the front wall of the cab for 6 additional points to bolt the camper to the cab. We still need to skin the outside exposed wood with some sheet aluminum one of my co-workers had stashed away.
Work day on the camper. by Rob Zulian, on Flickr

Cab floor section glued and screwed in place.
Work day on the camper. by Rob Zulian, on Flickr

Cab wall trimmed out with the fiberglass bolted in place.
Work day on the camper. by Rob Zulian, on Flickr

Cabinet rebuilding started.
Work day on the camper. by Rob Zulian, on Flickr

John had some oak paneled doors from other cabinet he salvaged and didn't have any use for them we could repurpose them for this project.
Work day on the camper. by Rob Zulian, on Flickr

Work day on the camper. by Rob Zulian, on Flickr

Work day on the camper. by Rob Zulian, on Flickr

Framework completed.
More work by Rob Zulian, on Flickr

Front corner was cut back to allow for clearance to my drivers seat. You'll notice the cab wall opening is cut open larger than the original version. Again this was done due to interference with the front seat not allowing it to move all the way back and have the seat back in a position I find comfy.
More work by Rob Zulian, on Flickr

This area will be very usefull. Lower cubby will contain the fuse panel and be the wiring hub for the camper. The middle vertical panel will be where the solar control panel, battery monitor panel, usb charge ports and switches will reside. The upper cubby will be for storage of small items.
Cabinet work. by Rob Zulian, on Flickr

Cabinet framed out with the oak trim. Still need to hang the doors.
Cabinet work. by Rob Zulian, on Flickr

Cabinet work. by Rob Zulian, on Flickr

The countertop will be cut out of stainless steel and inset on the top.
Cabinet work. by Rob Zulian, on Flickr

The cabinet is a large hurdle to get completed. All that is left to it is hang the doors, sand, stain/poly. Next phase is the inside of the roof. The stock headliner was water damaged and falling apart. So it's getting pulled along with the fiberglass batting insulation. Higher density foil backed insulation will be going back in, wiring run for the solar panel, lights and vent fan. The headliner going back in will be a plain white shower wall board. The wallboard is fairly thin/light and the white will brighten up the interior even with the lights off. Plus side is it's water resistant. We will probably reconstruct the lift panels in round metal electrical conduit and make a stronger setup than the plywood panels that are warped to hell.

From there, the camper needs the lower bench redone and the floor stripped of carpet and recovered in a vinyl flooring of some type. Then it's time to drop the camper on again.
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Old 02-02-2018, 02:52 AM   #303
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Re: My K5 Blazer Story.

Great progress. That seal looks solid.
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1991 V3500 L29 454 4L80E NP205 D60/14 Bolt 4.56's
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Old 02-03-2018, 12:37 AM   #304
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Re: My K5 Blazer Story.

Quote:
Originally Posted by MTCK View Post
That seal looks solid.
yup, very good idea
you got some very handy friends..
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Old 02-03-2018, 10:57 PM   #305
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Re: My K5 Blazer Story.

Quote:
Originally Posted by dieseldawg142 View Post
yup, very good idea
you got some very handy friends..
Thanks guys. The seal/top section came to me after saving a ton of FWC Blazer camper pics by google image searching. Found one pic in all of them that looked like somebody did the same thing, but no other detail came from it. After getting the section of top and measuring up the gap it was pretty easy to figure out. Hardest part was going through the process of cutting it to size. Fiberglass is some nasty stuff.

Yep, those two guys have been a major blessing in this project. Without them I'd be using a sawzall to get stuff done. We trade help as they both have Jeeps that need work too. We put a complete lift on Shane's old YJ wrangler last summer. Plus they are a riot to go camping with. Lots of fun for sure.
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Old 02-11-2018, 12:28 AM   #306
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Re: My K5 Blazer Story.

We had a rare storm coming our way today and I had it off too. So my buddy Bill and I wanted head west and see what trouble we could get into. I loaded my dog, some drinks and snacks and we took off.



Heading out of town, the snow hadn't got too aggressive yet. Just cold. Like 17 cold.



Heading up hardscrabble with a fresh layer of frost on the trees.


On the trail. Not sure how the aspen trees got to look like this. But not much snow to play on.


At the top. 11,450ft of elevation. Doggo needed to stretch her legs.



We are higher than the storm below. The normal view here is a wide valley that reaches to the mountain range on the other side.


Poser shot..


Coming down. At about 9,400ft just above the cloud.


Coming off the trail had is closer to Walsenburg so we ended up driving that way and rolling back up I-25 in the heart of the storm. No pics as all it was white. Not much visibility and doubled the normal time for the drive.
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Old 02-13-2018, 10:48 PM   #307
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Re: My K5 Blazer Story.

Just a note on the top. I doubt you will run into this as your cut down fiberglass shell mounting method will eliminate what i ran into.
Before i mounted the camper on my 79 i removed the rare cucv artic kit cover that was on my 79. That being said i put the screws back in their empty nut zerts to prevent leaks. That was a whoopsie as said screw held up the front part of the camper a wee bit which caused an air and water leak issue.
That was a unique problem that i am sure no one but me will run into in the next 1000 years. Lol. However i'd make sure those screws will not rub holes in the roof of the K5.

DW
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Old 02-14-2018, 12:34 AM   #308
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Re: My K5 Blazer Story.

Quote:
Originally Posted by 1976K5CHALET View Post
Just a note on the top. I doubt you will run into this as your cut down fiberglass shell mounting method will eliminate what i ran into.
Before i mounted the camper on my 79 i removed the rare cucv artic kit cover that was on my 79. That being said i put the screws back in their empty nut zerts to prevent leaks. That was a whoopsie as said screw held up the front part of the camper a wee bit which caused an air and water leak issue.
That was a unique problem that i am sure no one but me will run into in the next 1000 years. Lol. However i'd make sure those screws will not rub holes in the roof of the K5.

DW
Good eye. I've got clearance between the camper and the roof that is double of the thickness of the heads of the screws. Now my heavy butt might get the camper cab over floor to flex and touch, but I'll have to climb up there and have somebody look once the camper is loaded.
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Old 02-14-2018, 07:34 AM   #309
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Re: My K5 Blazer Story.

I am guessing the original design relied heavily on the weight of the camper bed area to seal the cab since it did not use the forward fiberglass top bolts to in essence pull the camper forward to seat it on the seals.
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Old 02-15-2018, 12:30 AM   #310
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Re: My K5 Blazer Story.

Quote:
Originally Posted by 1976K5CHALET View Post
I am guessing the original design relied heavily on the weight of the camper bed area to seal the cab since it did not use the forward fiberglass top bolts to in essence pull the camper forward to seat it on the seals.
It's funny in all my online searching I've come across a couple of Blazer FWC units that did in fact have the forward bolts to join the camper to the back of the cab. They did not use anything other than camper tape on the outside vertical wall to the back of the cab for sealing though.
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Old 02-15-2018, 01:05 AM   #311
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Re: My K5 Blazer Story.

Tomorrow i am taking my butt to the fiberglass shop and i am going to get pictures of my new 1k camper door! Its been a week and i can't stand myself. Lol.
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Old 08-12-2018, 10:11 PM   #312
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Re: My K5 Blazer Story.

I guess I should update the thread since I've been using this thing all summer.

So picking up on the cabinet construction. This got moved forward on a faster pace since my friend put his house on the market at that moment so we needed to get it together soon. We got the doors hung and added other little bits to the mix.

Cabinet work. by Rob Zulian, on Flickr

Cabinet work. by Rob Zulian, on Flickr

The cabinets really being the only thing left to get done inside, we ripped the roof off at my house and went back to John's to install the camper. The tailgate proved to be a pain as one of the bolts for the hinges on the body side had a head snapped off some other time and would not facilitate removal. Had to take the hinge off the gate just to get the gate off. (I actually didn't extract the broken bolt and hinge until prep was happening for the desert trip)
Camper install day! by Rob Zulian, on Flickr

No pics taken of the install as it didn't look any different than the last couple of times it went off and on. But once it was on I stopped on the ride home..
Camper install day! by Rob Zulian, on Flickr

Looking back into the camper you can get an idea why I deleted the fridge as my seatback is right where it would have been.
Camper install day! by Rob Zulian, on Flickr

Still need to build the lower bench at this point..
Camper install day! by Rob Zulian, on Flickr

Once home I could get to business on sanding the cabinet and doors down for a fresh stain/poly.
Camper work day by Rob Zulian, on Flickr

Camper work day by Rob Zulian, on Flickr

I was able to use my onboard air compressor to blow out the dust after sanding.
Camper work day by Rob Zulian, on Flickr

Lots of room to work inside with the top up. The stuck hinge was a great spot for my tumbler as I worked though..
Camper work day by Rob Zulian, on Flickr

I also got started with the needed 12v goodies I had planned for the camper side of things. With the plans for a 12v fridge eventually I ran 12g power and ground from the aux battery to this point. Added 6 circuit (should have gone with 8) fuse panel and power/ground junctions blocks. The entire camper is switched so it can be completely shut off to limit drain when parked/not in use.
Camper electrical by Rob Zulian, on Flickr

I kept the 110v plug that was already on the outside of the camper and ran it to 1 outlet with a GFCI breaker. At most I might run a shop vac or my laptop power if I'm plugged into shore power at a campground.
Electrical by Rob Zulian, on Flickr

I changed out ALL lighting for LED. Crazy bright and tiny power consumption. Like under 1.5 amps with two of these lights on full.
Electrical by Rob Zulian, on Flickr

Electrical by Rob Zulian, on Flickr

Added a GM underhood reel light to the back near the door too. It's using a LED bulb array too. Stupid bright. Also added a inside switch for the outside porch light above the reel.
Electrical by Rob Zulian, on Flickr

The new porch light. Again, it's LED as well.
Electrical by Rob Zulian, on Flickr

Then I got a little nutty. I added some color changing LED light strips that would normally be sold for lighting up the inside of a truck bed. Really bright, but the plan was using the red color when one might need to get up and use the "facilities" in the middle of the night and not mess with your night vision. Plus it don't attact bugs as much.
Lights! by Rob Zulian, on Flickr
Lights! by Rob Zulian, on Flickr

Lights! by Rob Zulian, on Flickr

I finished up my little panel where the stock ashtray would normally reside. One thing I found on the previous trip is a need for 12v/USB ports for phones, cameras, ipad, gps. So I added a two port usb to my panel with the aux battery control switch and onboard air switch. The little switch on the top kills power to the USB since it's lit all the time, so I don't kill power.
Electrical work by Rob Zulian, on Flickr

Some of the wiring in the cabinets. In total, there 4 more double USB ports in the camper and two more 12v sockets.
Electrical work by Rob Zulian, on Flickr

Electrical work by Rob Zulian, on Flickr

Another repurposed ashtray location.
Electrical work by Rob Zulian, on Flickr

In the cabinet.
Electrical work by Rob Zulian, on Flickr

My sisters even got in on the action. I had expressed an interest to copy some of the interior of the newer FWC Woolrich edition as imitation is the most sincere form of flattery. They worked up some buffalo plaid curtains and had enough left over to make a couple of pillows too.
Trimmings by Rob Zulian, on Flickr

Custom curtains for the camper. by Rob Zulian, on Flickr

Custom curtains for the camper. by Rob Zulian, on Flickr

Got Shane back over so we could put together a simple bench that reused the orginal cushions. After using it for three trips this summer, it will be reworked.
Bench time by Rob Zulian, on Flickr
Bench time by Rob Zulian, on Flickr

I wanted a way to monitor my power consumption. This little panel was found on Amazon, includes a 100amp shunt for the current measurement. It's installed above the lower front cubby. I can follow the battery voltage, current, watts and total watt/hours. It's pretty cool to know what is going on in the system.
Bench time by Rob Zulian, on Flickr

I needed some kind of way to carry a spare as the intended location of our desert trip would have us MILES off pavement and mooching a spare from Larry just woudn't cut it. So my buddy Bill and I whipped this up over a weekend. We had to add a hitch (Larry had a spare in stock) and some square stock with a couple of bolts we got a swing down unit. Bill added the step to make it a little easier to get in and out. This will change too. That dang tire is friggen heavy!
Final work day before trip by Rob Zulian, on Flickr

That pretty much catches up to where I was at prior to the desert trip. Not much has happend other than using it and fixing the lower bench where it came loose.
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Last edited by Zoomad75; 08-12-2018 at 10:23 PM.
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Old 08-20-2018, 10:54 AM   #313
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Re: My K5 Blazer Story.

Great update. I dig all the little details like the matching curtains and pillows. Have a make and model on the electrical control center?
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1991 V3500 L29 454 4L80E NP205 D60/14 Bolt 4.56's
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Old 08-20-2018, 09:05 PM   #314
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Re: My K5 Blazer Story.

Quote:
Originally Posted by MTCK View Post
Great update. I dig all the little details like the matching curtains and pillows. Have a make and model on the electrical control center?
I picked the panel up on Amazon. Here's a link to it.
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

The whole thing is backlit like indiglow and during the day it makes it easier to see in the day. At night though it's brighter than you think. It does have a little switch to shut it off though.
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Old 08-27-2018, 11:42 PM   #315
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Re: My K5 Blazer Story.

The camper is cool. I like seeing the rebuild on it. Good work and good progress. Hated to see that your Cobra CB radio died. I have one almost exactly like it going into a truck.
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Old 08-27-2018, 11:59 PM   #316
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Re: My K5 Blazer Story.

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The camper is cool. I like seeing the rebuild on it. Good work and good progress. Hated to see that your Cobra CB radio died. I have one almost exactly like it going into a truck.
Thanks! I was bummed on the CB too. Had I not have the deal on the Uniden drop in my lap for a good price I probably would have found a shop to repair it. It probably would have cost me almost as much as a new one to fix though.

I still have it. But then again I have a 23 channel GE radio that my Grandpa ran in one of his cars. I don't think it transmits. But it's cool to see a 23 channel radio and remember him using it so I keep it.
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Old 08-28-2018, 09:09 AM   #317
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Re: My K5 Blazer Story.

Did you or Larry do a write up on this year's desert trip? If so, can you share a link?
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Old 08-28-2018, 10:42 PM   #318
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Re: My K5 Blazer Story.

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Did you or Larry do a write up on this year's desert trip? If so, can you share a link?
Yes I did, the original can be found on CK5.com here:
https://ck5.com/forums/threads/2018-desert-trip.334182/

I started a version on here, but since it would not copy my photo links I kinda stalled out on completing it.

But the full version is over there to read.
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