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irab88's 1983 Coleman Sun Valley Build-Up Thread

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Old 12-11-2011, 10:44 AM
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Hahaha.... Yeah, lots of guys even in L.A. don't touch Aluminum or Cast Welding any more. My machinist does it, every day(Heads, etc.), but most are hard pressed to find a person to do it other than Him, Kelly's, maybe 2 others.
Old 12-11-2011, 06:17 PM
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Scary that folks out there are getting their welder's papers without touching alum./cast... or are'nt keeping their skills sharp working on all materials from time to time.
Old 12-12-2011, 09:59 AM
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what still needs to be welded and cut

-all red circles: weld
-all blue circles: cut and extend ~.75"
-green pieces: need to cut or modify
-all gray pieces: done

Old 12-12-2011, 10:40 AM
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Does'nt look like it's too bad of a modification Ian...

What was your opinion on my solar panel suggestion? If you want to go with them or "rough in" for them it may be an idea to add an extra brace or two to give you a place to securely mount them to.

These also might be an idea if you want to put some Yakima/Thule landing pads or some scrap yard roof rack rails so you can put a rack on top to carry a canoe/bikes etc.

they'd also make the roof a little stiffer without adding a lot of weight which would help protect it from dents and dings from branches/hail etc.

another idea [while I'm on a roll here lol] if you're going to redo the floor consider some hard-wood look vinyl strips they'd give your porta-casa a real high class look. (real hard wood would be nice but I don't think it can handle the temp./moisture extremes and it would weigh too much)... Check marine suppliers I think you can get some that looks just like the teak/mahogany they use on high end yachts...
Old 12-12-2011, 10:54 AM
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solar: i can get 100+ watts for ~$100 on ebay, so i probably will add them at some point.

cargo/support rails: only if i'm putting stuff up there. right now, i want to get this thing done so i can use it at rausch creek. this roof is the only thing stopping me

support: sometime in the future. if this roof holds fine, i'll add stuff on it later

floor: there's a hab4humanity restore right up the road, so i think that's what i'll use.

i'm really anxious to get this roof done! aaaaargh!
Old 12-12-2011, 01:47 PM
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for reference

truck side:


trailer side:
Old 12-12-2011, 05:23 PM
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some pics & progress!

picked up the last of the material



test-fit the outer channel





the front and back piece are dead-on

and on to wiring. did this tonight:

the simple circuit



and the soldering begins!



done. that was quick



it fits in the box!



truck side of the wiring



notice anything, uh, peculiar about this? (besides the "red" paint)



and the trailer side, so far


Old 12-12-2011, 06:46 PM
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Looks like you're using the 4pin to run the turn signals on the trailer based on what I see in your diagram... don't know why though...
the truck side has only 3 wires used you cut out the ground line is what's "peculiar" lol...

you thinking of adding trailer brakes in the future?...

btw nice trailer icon

Last edited by aviator; 12-12-2011 at 06:53 PM.
Old 12-13-2011, 05:22 AM
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the plug i have for the truck side is made for the trailer side (and vise-verse for the trailer). and yes, i'll only be using 3 of the 4 wires. that plug will be used for the amber turn signals only. the plugs got switched to avoid being plugged into a standard 4-way plug.

basically: if the truck is towing a standard trailer (not mine), all lights will function normally. if my trailer is towed with some other truck, the lights will work normally (the amber turn signals won't light, though). however, if i tow my trailer with my truck, the red lights are for stop-only, and the amber lights are for turn-only.

i know, it's one of those things that's easier to show than explain. i'll get a video up whenever i have all the lighting done.

and yeah, possible brakes much later

Last edited by irab88; 12-13-2011 at 05:24 AM.
Old 12-13-2011, 08:30 AM
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Ahhh okay... wondered why you had that massive relay box action going on...
Old 12-13-2011, 02:41 PM
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i like that "porta-casa" name... hafta play around with it. i'm thinking "rota-domus"

the trailer got moved the other day...



not far, but enough to shake the cobwebs off
Old 12-13-2011, 09:38 PM
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heh heh heh just thought of the one thing you need to add to that trailer... well two things actually... one of those zip on add a room things for under the awning and ...get ready for it... an inflatable hot tub... that would make it totally shag-a-licious... yeah baby!
Old 12-14-2011, 04:41 AM
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yes! hahaha

Old 12-15-2011, 07:59 AM
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trailer wiring being closer to done:



Old 12-16-2011, 03:11 AM
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we are not over complicating anything are we ??
Old 12-16-2011, 04:14 AM
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six relays and four fuses for the truck box (right), and two relays and one fuse for the trailer (left)... what's complicated?

Old 12-16-2011, 05:29 AM
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Why so many relays, I am confused. lol. And where did you get them boxes. Looks like a better solution then the shack's project boxes.

Last edited by xxxtreme22r; 12-16-2011 at 05:30 AM.
Old 12-16-2011, 06:01 AM
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the boxes are underwater boxes from ebay. pay no more than $20 a box including shipping. i'm going to glue everything inside with goop automotive, so the only holes to be drilled will be for wires. those holes will have a grommet, followed by goop to seal them all up. i want to make these water-tight.

all the relays. hold on, this'll take a while...

some trucks, like ford, have only 2 tail lights that perform all the functions of stop, left, and right. if the brakes are on and the left turn signal is on, the right tail light will be constant on while the left one flashes. all trailers are like this (not semis). i don't like it. (often referred to as "mixed" lights)

toyota trucks, on the other hand, have 2 tail lights for the function of stop, and two individual turn signals. my trailer is also like this.

now, i could take the easy path and just wire them directly across. seems easy enough, and it'd be a lot simpler. the problem arises when i want to pull a different trailer, or when i want to tow my trailer with another truck (like my dad's ford). the turn signals wouldn't work, and the tail lights might not even show stopping.

my solution was this: i wired everything on the truck and trailer to drive the lights like normal mixed trailers. then, i added a circuit to override it and power the individual turn signals, but only when that 4-pin plug was plugged into my truck's 4-pin plug. that way, i could safely pull any trailer or tow with any vehicle, and still be able to have separate turn signals when pulled behind the truck

(also, one relay per circuit takes the load off of the truck's circuit, increasing brightness)
Old 12-16-2011, 06:03 AM
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oddly enough, that makes perfect sense.
Old 12-16-2011, 06:06 AM
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That is why he works on airplanes !!!!!


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