Java's F450 RV

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    Java's F450 RV

    Should I port everything over or just pick up where we left off?

    Eithier way, subscribed!

    If you want to go to one spot for your info, port it over. If you are happy jumping back and forth, start from where you left off (tire issues if i remember right?).

    Glad to see this one way or the other. Thanks.


      Its just 88 pages to try to copy over..... Ugh


        If you value any of the info I would copy it over, if you are just blogging then continue.
        Glad you're here either way.


          Did you figure out the tires?


            Originally posted by granitestatedestroyer View Post
            Did you figure out the tires?
            Nope, toyo basically told me to fuck off. My local toyo dealer looked at the pics and figured it was a mfg defect. Hadn't seen anything like it.


              OK Here goes. Hold onto your panties....

              Feb 10 2017

              I have been half searching for a replacement for our Ski Bum truck (and E350 4x4 winnebago), I love the truck, but the long overhang and fiberglass construction limit me a bit. I had gotten a quote from Tri Van for an all aluminum body for an F450/550, and was keeping an eye out for cab chassis to com up cheap on CL.

              Then I found this truck, Nearly the same body I had a quote for, on a 2008 F450 4x4 frame, which had been stretched 36" to allow for nearly no overhang. It was built as a chase truck for a UTV racing team. I wasn't really ready to pull the trigger for a new truck, but this was too good to pass up. Deal was struck and the truck headed to my driveway.

              About the truck, Its on its second motor, the first owner towed horses with it, she attempted to drive it home after the CEL came on, #8 injector had failed, rod ventilated block. PO bought it, had a local shop drop a long block in and used it to go to Vegas for races a couple times. Then it sat, this is good and bad, it has ~4k miles on the new engine, but it leaks. A fair bit. Oil pan, valve covers and #6 glow plug harness connection. And the dreaded flex joints in the up pipe. Not the end of the world, but a lot of stuff to remove to get to the problem areas. It seems most procedures on these new trucks is cab off or trans out. Fun.

              Everyone home in the driveway, I need a bigger driveway for this many large trucks...

              The box is a bare shell.The cabover is 4' tall. Very high interior roof. First order of business is the roof, two vents were framed in, and covered over with plywood and Plexiglas. They leak. So two Maxxfans were ordered and have arrived!

              Maxxfans and sealant, first of many parts deliveries.

              The back is insulated barn doors. They will be staying. One will be for exterior storage, the other can be opened to the end of the bed if its used in summer. Four 6V 250Ah AGM batteries can be seen here too.


              Condensed version of our current layout. I think it works pretty well. Toilet will just have a curtain, leave a bit more space at the door. Cabover bed for the kiddo, back bed for us, fixed dinette. Counter space is limited, but will have a fold out over the crawl through, and is across from the dinette table that can be used as well. Small bar sink, three burner RV cooktop, and the space below used for a marine fridge. Exterior storage for skis, other tall stuff at the back. Still debating on propane tank placement, I am thinking two BBQ style tanks on a swing out on the drivers rear.


              First order of business is getting the crawl through, windows and doors framed and cut. The crawl through is going to be a challenge, I have some thinking and blue taping to do still, but it should be doable. Accordion seal will be used there. If anyone has done this I am all ears.

              Once the framing is done I will have the entire thing spray foamed. I am still debating on ceiling thickness if anyone has input. Walls will be 1 3/4" foam with 1/4" plywood interior skin. Spray foam will be a big $$ item, but I fell it will be worth it in the long run.

              Then its on to interior finishes. Dinette and vertical walls I am thinking will be small steel tubing with a thin plywood skin. Maximizes interior spaces of the compartments that way.

              I am leaning towards doing EGR and DPF delete stuff to the engine while I am in there, but it adds a good budget hit. It may be a couple years down the road. Lift is a ways off too, but for most of what we do it should be ok for awhile. FS roads and snow/ice covered roads to ski areas. It has brand new tires that I wouldn't mind using up either.

              This will be a very slow build. I am very budget limited, so it will be plugging away a bit at a time as budget allows. I will need to sell the RV come spring, and would like to have this one done shortly after, but I think that may be a lofty goal.

              Feb 10 17 pt2

              hmmmm leaking roof "vent"

              Pull off plywood, scrub with MEK

              MaxxFan shroud, covered in sticky stuff.

              Roof hole #1 done! Only broke one screw off. Stupid stainless.


              More small progress. Climbed under, with tarp this time (i managed to park on the non gravel, ie mud section of my driveway), to investigate oil leaks. Headlamp, UV light and torque wrench in hand.

              Oil pan bolts are to torque spec (9.5 ft lbs, really?!) but are dripping from the heads around the back of the pan, front looks dry, that makes me thing its seeping past the bolts/threads, but could be running down from above. I just don't see it getting to the heads of the bolts.

              Valve cover area on passenger side is wet and running down the block, may be valve cover gaskets, may just be the glow plug harness on that side (DUMB design). Likely both though. Still determining if I want to tackle those or farm it out.

              Stripped the interior down. I was getting a bit of water at the back edge of the cabover, need to find it. I had a suspect in mind.

              Marker lights were the suspect, and sure enough, you can see the tel tale dribble line coming out the bottom. (there may still be a little coming in from the gutter-body joint, but that is TBD)

              Passenger side is better, but still a little drip.

              In case anyone is interested, here is how the panels clip together and form the ribs.

              Brown Santa has been leaving me lots of goodies.

              12/3 SJTW for the 12V circuits. I could buy 100' extension cord cheaper than the wire, go figure. Made in the USA too.

              14/2 Anchor Marine Tinned cooper wire for the 12V circuits, 250' roll, also Made in the USA.

              Also got a switch panel and the interior lights I will be using.

              I only had an hour or so, but I started on the cab.

              Stripped the back wall.

              I knew there were some mice at some point as I found some turds under the back seat.... But they made a home in the middle seat belt housing. No fresh, but stinky mouse pee. Somehow they seemed to have made it above the headliner too... I really didn't want to pull that.

              Planning for the pass through, it looks like I can unbolt and slide the box back about 6" I hope thats enough! And of course this is a glued in back window.

              Feb 11 2017
              wiring rough in is just about done. I used that entire 250' roll of 14/2, and i didn't use it for the lighting circuits (18 gauge for the LED's). I didnt quite expect it to go tat fast! I need another 30' probably. Need to run circuit for the heater and water pump still. I will likely run those ousisde the wall later on.

              Door and double pane windows have been ordered too!

              Two main areas for the elec, under the bed, where the batteries, inverter/charger fuse panel and breakers will live, and the end of the cabinets of the opposite side, where all the switches will be. The rest is lighting circuits, and conviniance plugs. I need to figure out a way to keep the end of the wires poking oout of the walls/ceilings where I want them, duct tape may work, but the entire inside of the box is covered with frost at the moment, its cold out...

              I got some rigid insulation to start furring the ceiling down with as well!

              A little more every day is the idea right?

              One table saw, one sheet of 3/4 ply turned into little pieces.

              Got one wall almost done. It was butt berkeleying cold. The missing areas are doors/windows.

              So I tried insulating the aluminum channels. That was a failure. The foam would only expand ~6" either side of the hole, no matter how much you tired to pump in. Im not going to put a 15/64 hole very foot.... Looks like they will remain uninsulated unless someone has a genius idea. Thoughts? I am trying to avoid cold bridging.

              You can see the foam puking out of the holes in a few spots here. That stuff was not cheap.

              Got the ceiling channels filled at least.

              Box of goodies is growing

              Battery interconnect cables. Check, CL score.

              Got an on demand hot water tank on Ebay, killer price, should be a nice unit, 60K btu's.


                Feb 12 2017
                My door showed up, but the UPS guys had their way with it , edges are good and dented in a few places....

                Picked up a used inverter/charger as well, only 1250 watts, but should run a microwave (i hope!). Charges at 55 amps, a bit slow there as well, but the price was right. Came with a 200A Blue sea breaker too.

                Whats in the crate?

                Windows!!! Not fancy flush pane ones, but they are double pane insulated ones, they latch and slide very nicely, I am very happy.


                headliner dropped and moved forward.

                No going back now! It was a bit scary to take a sawzall to my new truck.... Rough cut in the box.

                Window out, got 3/4 of the way around, then it broke... ugh


                Need to cut the inside lip down to 1/2" still. Ran out of blades.

                Window infill pieces, ran out of time today....





                Got the window infill panels done. Used the cutout from the box! Has a rib on either piece, makes a nice stiff panel.

                Almost done! Cutting the last bit of the cab and box.

                done, that was a bitch!

                Whatever aluminum they used for the floor is HARD


                Starting on the gasket.

                all done

                Connected! just need to get the cab vents back in now.


                Just about caught up on this thread now...

                More big holes this weekend!

                Window is just temped in, so the red tape is water proofing...

                One next to the door too, hard to get a pic as its next to the garage.

                Opens the inside up a bit!

                Said good bye to my little trailer too That was my first big fab project.


                Long list before insulation.... Got a little more done last night.

                Reinforced the large window. It was a little floppy, and I didn't wan the spray foam to hold it crooked. Used a piece of oak there.

                List, done. Way more of a thrash than I was expecting. All the little stuff adds up...

                All the furring s done, all the wires wrapped, taped, glued in place.


                a bit more....


                Now for the nasty part... Grinding it all flat.


                  Oh I loved this build!!!


                    Glad you are moving it over. Gives me an excuse to read it all again!


                      Trying to catch this thread up.....

                      Annnnd Done!!!

                      First panel up

                      Got another sheet on the wall last night. Aiming for one a night for the weekdays.

                      One more panel!

                      And the heater getting a bench run. Cant decide if I want to do a separate tank or pull from the main tank.

                      Cleaned the garage last night. I now have about about 6'x15' of usable space. Soon to be cabinet shop.... Also found out the cabover is still leaking.... Ugh. We got more than an inch of rain yesterday, once it drys out a bit Ill have to caulk it from the outside.

                      Knocked out the bed frame. Its dimensions kinda drive everything.

                      Put about 70 miles on it Sunday, picked up the ceiling material. Its going to be knotty cedar T&G. Smells delicious! But it was smoking again, I think it may be leaking oil onto the exhaust, but it seems to do it randomly. I need to crawl under it again and see whats up.

                      Drivers Side wall done

                      Ceiling started. Definitely a rustic cabin kinda look.

                      Test fit one of the lights Ill be using. I hope they are enough light! They are 3W 120lm each.

                      I was trying to get the two windows I have cut in yesterday as we are supposed to get 2" of rain today... I have had a cold coming on, and that sure didn't happen.....

                      I did get one in, and it was not fun. Turns out my walls are only 1 7/8" thick, not the 2" I planned on. And to make things worse the foam was a bit thin around the windows, this let the plywood bend in even more. So I have to cut a bunch of shims, and make things kinda the right thickness again. Then.... The wall has a big bow in it, vertically. So I couldn't just use the foam strip to install the window. Its glued in like a berklyer now. After getting that in I was spent. The good news is my new patterning bit for the router work great at cutting the holes.

                      Hole cut

                      Window in

                      it got dark....

                      My stairs came though, and they fit in the under body box! It was close, but they fit.

                      I also picked up a battery combiner, its rated for 200A continuous, so it should be up to the task. Another CL score, $20!

                      Since the old ship has sailed, time to kick it in gear.

                      Good bye old friend. You will be missed.

                      Since its the time of the year it usually rains in the PNW, dry weekends must be used to their fullest.

                      I was in a bit of a hurry, so not too many pics.... But window #2 is installed.

                      Window #3, drill 4 big holes. Connect the dots.

                      Cut and fit interior panels.

                      Slap in window.

                      Stair bracket on.

                      Stairs. Yeah my garage is a mess and very full...

                      Fridge acquired. They only had one left in stock locally so it was snapped up. Isotherm (made by webasto) 4.7 cu ft drawer unit, which will be nice as its under the counter top, no getting on your knees to see in the bottom shelf. Its REALLY nice.... But my wallet hurts. Its a DanFoss compressor, 12v and 120V, burns 429 watts/24hr on avg.

                      Made a little time lapse of the weekend.


                      At the start of the weekend.

                      Wrapped up the ceiling

                      Sanded and stained last night. Changing color

                      First coat done

                      Got a bit done this weekend.

                      I love these splices. Crimp on, self adhesive shrink wrapped. Good stuff.

                      Got the LED exterior light done.

                      Fan trims and interior pucks in.

                      I had to hook them up to see if it was going to be enough light. I was worried it wouldn't be as they are quite small. Its a good amount of light!

                      Started framing up the rear storage/wall. Its 1" .072 steel, this give me a 1" area I can insulate, and gives me some structure to support the bath wall from.

                      In place. This will be the exterior storage.

                      Bathroom wall and bed frame just about done. Cutting stupid angles wiht a skill saw sucks.

                      18" clear under the bed frame for storage. The plan is to have it lift up for access from inside.

                      And that catches up this thread! ok we will slow down to real time updates now...

                      Feb 23

                      Here is the panel

                      Got the benches cut and partly together

                      And i have enough scraps of maple 1x3's for the kitchen cabinet face frame!

                      Got a fair bit done yesterday.

                      Cabinet will separate the bed/dinette area. The bottom will have a pull out drawer for trash and recycle. The middle will be a pantry drawer, and the top will be a shelf open to the dinette side. It also created the back and base of the bench seat.

                      Bench sitting in place. Heater or water tank will go here. Like heater so its closer to the center of the truck, but that means small water tank..... Thoughts on heater not close to center? It would go right at the front wall, under the other bench.

                      All together


                        This is kinda fun going back thru all this. Also what a fuck ton of work! And nice to not limit number of pics per post!!!


                          Spent an hour or so trying to figure out why my reverse lights dont work... Fuse is good, swapping relays made no difference. Im getting ~half a volt at the light connections.

                          So possibly a break in the wire somewhere, which I think is unlikely, all the rest of the wiring has been impeccable, and the tail lights still work, or the reverse switch at the trans is toast.

                          Other half of the dinette sitting in place

                          Im thinking heater and water pump will go here, just have to check that I can sneak the intake and exhaust out, its right above the gas tank. I will have to build a riser for the heater to sit on as well, not quite enough room with gas filler box there.

                          Stove came too, ebay special with dents... But its got a nice flip down glass top for when its not in use.

                          Pulled the tail light panels. Lots of room there. Need to figure out how to put them on a quick release. Ill take ideas there!! Passenger side will get poop tank, drivers will get gas tank for the heater.

                          ere is a floor section for anyone curious, aluminum (ACTUALLY STEEL), some coating (the grey), then a boat load of bed liner.

                          Cut hole for heater intake and exhaust

                          Bolt down heater and run exhaust.

                          Put the slats on the bed. One skinny one since math is hard.

                          Four fucking heavy batteries.

                          Harness mounts make great battery mounts too

                          Started wiring.

                          Time lapse of the weekend.


                          Got to let my inner OCD out last night

                          Final wall panel went in. Was planning two pieces.... Did it in one instead so my hole was off a bit. Trim will cover it. Second dinette bench is in. I am thinking I may pull it back out and shrink it another 1/2"....

                          The UPS guy must love me.... And I have a very forgiving wife for letting me pile parts in the house. Thats the tank for the heater, 3 gallons, will be mounted outside.

                          Poop tank and parts are in.

                          Tried this floor, not doing it for me... It was the only "grey ish" one that was in stock at HD. Will see what else I can find.

                          Fuck am I getting tired!


                          Underlayment going down. Green and red is the same stuff, I just had a piece of the green left and it fit just right there.

                          Here is where I quit last night. Found some flooring we liked finally. Its a vinyl plank with a "foam" core. Claims to be water proof.


                            Late night last night... Didn't take many pics.

                            Finished up the floor

                            Kitchen cabinet in (well mostly in...)

                            About 30 hours till departure....ouy

                            Got home before dark. outside shot! Will need some air in the bags...

                            Switches actually running the lights! 12v meter and two usb ports there as well

                            rats nest.....

                            Pooper placement confirmed

                            Black walnut scraps for sink infill cutting board

                            MARCH 5TH, FIRST NIGHT IN THE TRUCK.

                            Fawk yeah!

                            Sent from my SM-G900T using Tapatalk


                              update since I was in a giant rush yesterday.

                              pooper in

                              Prototype ski storage

                              Temp counter in

                              Bed done, after the first night, im really happy with the Amazon memory foam mattress. so cushy

                              Temp cooking

                              Stairs work well

                              A little more progress last night. Gas strut installed on the bed. Only ended up needing one. Seems to work just fine.

                              Pretty decent storage access. I may put a divider in to keep things from migrating towards the back...

                              Poop tank valve going on. What a huge PITA. When the company wants to sell you a bag of abs shavings just buy it.... I spent a long time with a piece of pipe and a paddle bit making shavings. I didnt realize how much it would take....

                              mmmm goobery

                              Fridge is in! And its pretty

                              Black tank fittings are the biggest pain in the ass you can imagine.

                              That was it for last night.

                              No real visible progress last night. Put a coat of finish on all the raw ply edges.

                              Also picked up the counter top material

                              Child safety device in place.

                              Now back to the heater. I couldn't get it to pull gas from the boat tank. After pulling the tank apart I think the pickup tube was just too big for the little pulse pump. It was 3/8" ish tube. So heat gun and a piece of 3/16 and wa la, new in tank pickup.

                              Since I haven't gotten a chance to install the tank yet.... ghetto rigging ensures. Luckily this is all very low pressure.

                              It works!! Box got to 70 in a couple minutes.... Too hot.

                              Exhaust location since I dont think I ever posted this. No smoke or smell on kerosene.

                              Not about that ticking fuel pump. Its loud (mounted to the wood spacer above the frame rail in a rubber P clamp). This will need some googling.