caravan chassis upgrade

Submitted: Friday, Jun 12, 2009 at 15:04
ThreadID: 69752 Views:18527 Replies:8 FollowUps:21
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a caravan topic a while back where someone built a caravan from scratch using that new plastic stuff showed the shell level with the floor....ie not cutout section for wheels

whats stopping one from making a new OFF road chassis and sticking it under a existing caravan chassis....stupid question I know...but what could be wrong with that idea
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Reply By: Member - DAZA (QLD) - Friday, Jun 12, 2009 at 15:25

Friday, Jun 12, 2009 at 15:25
No 1

*Would you have the off road chassis with the draw bar?
*What size is the existing chassis?
*What would be the weight of the proposed and existing chassis?
*What would be the height between floor level and the ground?
*What type of suspension would you use?

Geez I think I have asked enough questions lol.

Cheers
Daza
AnswerID: 369672

Follow Up By: Member No 1- Friday, Jun 12, 2009 at 15:59

Friday, Jun 12, 2009 at 15:59
most existing drawbars only go back to point near the suspension.

i was thinking a full length rails (6") right to back of van incorporating new draw bar under existing framework. New suspension (thinking springs) bolted to those new full length rails. This would effectively raise the van say 6".

dont worry about weight at this stage but comments welcomed.

yep the wheel arches might look abnormal
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Reply By: tim_c - Friday, Jun 12, 2009 at 15:31

Friday, Jun 12, 2009 at 15:31
You may find that the body/shell of the caravan and the fittings are all built stronger to resist more flexing and bumping around than a standard on-road caravan (at least, I'd expect them to be!)
AnswerID: 369673

Follow Up By: Member No 1- Friday, Jun 12, 2009 at 16:03

Friday, Jun 12, 2009 at 16:03
maybe.....but if taken easy i dont think it would be a problem
are the Jayco's ie eagle swans etc etc shells manufactured to withstand more rigours than a standard & and if so by how much.
but in any case i am a handy man..
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Follow Up By: Peter_n_Margaret - Friday, Jun 12, 2009 at 16:07

Friday, Jun 12, 2009 at 16:07
It is comon in the Kimberley to hear of overhead cupboards all finishing up on the floor.
If you are 'handy' enough to do that bit, keep going and build the whole thing.
That's what I did with the OKA. No regrets.

Cheers,
Peter
OKA196 Motorhome
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FollowupID: 637086

Reply By: HappyCamper - Friday, Jun 12, 2009 at 16:30

Friday, Jun 12, 2009 at 16:30
G'day #1

This maybe be the van you meant? Hope so, anyway!! LOL

Thread # 67983

Builing a caravan from scratch

Bronwyn ;-)
AnswerID: 369680

Follow Up By: Member No 1- Friday, Jun 12, 2009 at 16:41

Friday, Jun 12, 2009 at 16:41
yep, that is the one Bronwyn...and you shouldnt flirt with strangers...i'll skitch swmbo onto you..hahaha

notice that the chassis rails go right thru to the back and doesnt have any wheel arches so to speak of. my thought was...whats stopping one from adding full length 6" rails to an existing van?
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Follow Up By: HappyCamper - Friday, Jun 12, 2009 at 16:49

Friday, Jun 12, 2009 at 16:49
I'm scared!!

Send her around...I'm needing help with a knitting project, maybe she can help? ROFLHMO!!

Bronwyn ;-)

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Follow Up By: Member No 1- Friday, Jun 12, 2009 at 17:08

Friday, Jun 12, 2009 at 17:08
so am I...lol
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Reply By:- Friday, Jun 12, 2009 at 18:31

Friday, Jun 12, 2009 at 18:31
G'day,

Funny you raise this idea, I had been thinking of this myself recently. Thought it would be good to get an older van and modify it to off road status....still thinking of course. Roothy has done it to a degree with Project Vicky, modifying the draw bar, alko off road suspension, etc, etc all on an old Viscount!!

To get some further technical info contact Caboolture Carvan Repairs (http://www.caravanrepair.com.au/), they do repairs, draw bar mods, etc so will probably have the info you require.

Keep us informed if you go ahead with anything

Cheers
Ev
AnswerID: 369707

Follow Up By: Member No 1- Friday, Jun 12, 2009 at 21:10

Friday, Jun 12, 2009 at 21:10
yeah i saw that some time ago (2yrs) in the physio's waiting room
have tried recently to follow it up but the magazine is gone
the net hasnt revealed anything on how it was done
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Reply By: rumpig - Friday, Jun 12, 2009 at 20:21

Friday, Jun 12, 2009 at 20:21
nothing wrong with that idea at all.
i've sort of done what you are talking about with my old Millard 13ft van. i built a whole new chassis out of 125mm X 75 mm (i think going on memory) box section, and a new drawbar made out of 100mm X 50mm. i only wanted 125mm X 50mm like i have seen on other vans such as Jayco, but apparently you can't buy that size from the steel guys i rang trying to sorce it. the 125mm worked just right for my steps which is why i used that size.
i jacked the old van up and cut the so called chassis and drawbar off from underneath it, it was scary to see just how they used to build them back then. i used the old springs (probably should have bought new ones in hindsight) and then used new axels, rims and hubs to get same wheel track as my cruiser. made the new chassis up in the carport as a rolling chassis with the wheels and axel etc. once all made i dragged it under the van which was sitting jacked up and then lowered the van shell down into position and added some brackets to bolt it all into position. it took me and a mate 2 days over eater lat year to do the job. i already had sat down and drawn plans up to scale of what we were going to do, so all the thinking had pretty much been done, we just had to build it on that weekend.
i'll post some pics up soon and show you how it was done.
AnswerID: 369726

Follow Up By:- Friday, Jun 12, 2009 at 20:57

Friday, Jun 12, 2009 at 20:57
Great, can't wait to see the pics
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Follow Up By: rumpig - Friday, Jun 12, 2009 at 21:03

Friday, Jun 12, 2009 at 21:03
would have them up already except photobucket is killing me with how slow it's going. arrrrrgh
i forgot to reduce one of the pics and it won't cancel the upload no matter how many times i click Cancel
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Follow Up By: Member No 1- Friday, Jun 12, 2009 at 21:13

Friday, Jun 12, 2009 at 21:13
could you me email the pics?
rquinn1atbigponddotnetdotaul
thanks
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Reply By: rumpig - Friday, Jun 12, 2009 at 21:24

Friday, Jun 12, 2009 at 21:24
Take one old caravan



Jack it up with a trolley jack and then prop it up with car stands and saw stools (this was abit scarey getting it safe to work under)



Cut off all the bits from underneath you don't want. (Have fun as this job really sucks. sparks flying everywhere you don't want them. Lots of those skinny cutting discs and a 4" grinder did the trick though)



Set the new steel up on a level surface, we packed the saw stools so everything was dead level, and then squared it all up by checking diaganals.



The new chassis mostly built, just needs a few minor things and then to be flipped back over. wasn't that heavy, 2 of us flipped it over.



One rolling chassis ready to go under the van. The axel is abit further back then i would have liked (looks alot worse in this pic), but this will be allowed for when all heavy stuff goes behind the axel to help with towball weight.



Drag the chassis under the van and lower it into position ready to weld fixing brackets in place.



The new extended chassis with storage box on front.




AnswerID: 369738

Follow Up By:- Friday, Jun 12, 2009 at 22:35

Friday, Jun 12, 2009 at 22:35
Awesome job mate, well done, good on you for giving it a crack!!!!

How much would you say it cost you to do it?
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Follow Up By: rumpig - Saturday, Jun 13, 2009 at 09:22

Saturday, Jun 13, 2009 at 09:22
including the new rims, tyres, hubs, axel and steel for the chassis it was somewhere around $1500 i think from memory, i did it 2 easters ago so memory is hazy on actual cost, but that figure seems to ring a bell. the big storage box on the front was extra but i don't remember how much, all up somewhere around $3000 i think if the box is included in the price. we looked at upgrading to a newer van but just couldn't afford to do it at the time, i know i have over capatilised on this van, but it will serve a purpose for a few more years yet.
haven't got any pics of inside, but currently in the front of van where the dining table folds down to make nearly a double bed, there's a cot for our 18 mth old and the rest is our 6 yr olds bed. they are both growing to big for this setup, so i'll probably pull it apart and make a set of bunk beds in it's place. i've rebuilt all the kitchen and our double bed, it has a big pull out draw underneath it just as the front bed does for storage, the only thing i still need to rebuild is the linen type cupboard as you walk through the front door on the right hand side.
the front storage box holds all our chairs and rubber ground mats and the bbq you see in the last pic on the drivers side. on the passenger side is a 40 ltr fridge on a slide that pulls out like you see in the back of 4wds. there used to be an 80 ltr engel combi fridge in there but i have changed it over to the 40 ltr to try and loose some weight off of the drawbar. under the bed at the very back of the van is 2 X 110 AH batteries which keep us going for a few days without needing power when we are away, never ran them flat yet but i'm guessing we'd get atleast 4 days without needing to charge them, possibly even more.
i only built it like this as a temporary short gap thing whilst we look at getting a bigger van later on. if i was planning on keeping the van forever i would have done things like the suspension different aswell as possibly changing over the brakes to disc and electric.
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Follow Up By:- Saturday, Jun 13, 2009 at 14:46

Saturday, Jun 13, 2009 at 14:46
Yes, may have over capitalised but not by much and well worth it I would think. I would do as you have done and remodel the inside.

Overall it is a great effor and I appreciate the info you have provided.

Thanks mate
Evan
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Follow Up By: Member No 1- Sunday, Jun 14, 2009 at 10:02

Sunday, Jun 14, 2009 at 10:02
great work rumpig
its got my attention

now...which caravan????
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FollowupID: 637300

Reply By: RovingOz (QLD) - Friday, Jun 12, 2009 at 22:39

Friday, Jun 12, 2009 at 22:39
Here's a resurrected 1967 Viscount that's been to Boorooloola and back a few times.

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AnswerID: 369751

Follow Up By:- Friday, Jun 12, 2009 at 22:41

Friday, Jun 12, 2009 at 22:41
Great stuff, you guys are an inspiration!!!
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FollowupID: 637163

Follow Up By:- Friday, Jun 12, 2009 at 22:45

Friday, Jun 12, 2009 at 22:45
G'day
when you put the checkerplate on the front did you just put it over the original panel or did you remove it and replace it with the checkerplate?

Cheers
Ev
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FollowupID: 637164

Follow Up By: RovingOz (QLD) - Friday, Jun 12, 2009 at 22:55

Friday, Jun 12, 2009 at 22:55
All done by ingenious previous owner. 12vlt lighting, battery, microwave, air con, 2x60lt water tanks, pump, heavy duty leaf springs, disc brakes. Tows very well.
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Follow Up By: RovingOz (QLD) - Friday, Jun 12, 2009 at 22:57

Friday, Jun 12, 2009 at 22:57
checkerplate is over the top.
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Follow Up By: rumpig - Saturday, Jun 13, 2009 at 09:29

Saturday, Jun 13, 2009 at 09:29
my sister inlaw has the same type of van we have and when her partner did the checker plate on his van (along sides not on front), he removed the old paneling and slid the new stuff up underneath in place.
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Follow Up By: Member No 1- Sunday, Jun 14, 2009 at 10:06

Sunday, Jun 14, 2009 at 10:06
another great job
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Reply By: Member - Duke (TAS) - Saturday, Jun 13, 2009 at 15:20

Saturday, Jun 13, 2009 at 15:20
Hope you Fella's got approval from DIO for these modifications,
Duke
AnswerID: 369813

Follow Up By: Member No 1- Sunday, Jun 14, 2009 at 10:05

Sunday, Jun 14, 2009 at 10:05
err
err
err


nah ...I cant be rude on here
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FollowupID: 637301

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