After
much use of our 1300L Unimog/Alaskan camper combination, both Kathleen
and I concluded that a bigger living compartment was in order.
The trick would be to find a platform that offers more room (a bigger
"footprint") and still provides good off-road capability. After
much research, I concluded that the Mercedes-Benz 1017A 10 ton 4x4
cargo hauler was just the ticket. I found one of these trucks "in
country" at Rob Pickering's place in La Junta, CO. Since we were
on the tail end of our east coast mega-trip, we decided to stop by and
physically inspect the rig. After seeing, and driving, the truck,
we concluded that it was the platform that we were seeking. While
on the road, we were also performing a search for an appropriate living
compartment to go atop the truck. The Alaskan camper has a rather
unique feature which is a top that raises and lowers. When
traveling, the top is down to provide a lower center of gravity.
When parked, the top is raised to allow head room. Our Alaskan, a
1978 model, has a manual hydraulic pump that is used to lift the
top. It only takes a few minutes, but it is somewhat of a
nuisance.
Kathleen's research on the web suggested that a Hi-Lo Trailer might be a good cabin. Further research showed that the company had recently gone out of business due to the recession and that there was a new unit of the correct length located in Colorado Springs, CO about 100 miles from the location of the 1017A. After seeing the trailer, we bought it on the spot. The trailer was half of the list price and while there were some issues that needed to be addressed, it was a good value overall.
We
towed the trailer to Rob's shop in La Junta to prepare for modification
and assembly of the combined unit. Due to Rob's schedule, we
ended up returning to San Diego first and then coming back to La Junta
a few weeks later when an open spot in the schedule was available.
The photos below are what we saw.
Kathleen
measures the height of the cab on the 1017 prior to purchase. We
were somewhat concerned about the overall height of the combined rig.
A
side view of the 1017A. This is the "before" photo with small
tires and dual wheels.
The
bed of the 1017 was big, heavy and just not needed. So, it was
unbolted and lifted off the frame with a pair of fork lifts.
The
naked bed shows two huge cast iron "saddles" that were pivoting mounts
for the bed.
These
mounts were massive and it is not clear to me why they were so
big. But, no matter, they were removed to make room for the HiLo.
We
drove the 1017A over a loading dock wall to test the articulation and
determine how much frame flex there would be in an extreme off roading
situation. This information is important in the design of the
sub-frame to support the camper.
We
towed the HiLo from the sales lot in Colorado Springs to La
Junta. The photo above was taken in a parking lot off of I-25
south of CS. The folks at the trailer sales were nice enough to
loan me some equipment (like a hitch extension) to allow me to safely
tow the trailer to La Junta. In the photo above, note that the
trailer is in the lowered, travel position providing low wind
resistance. Also note the gray side skirts that will be removed
and replaced with tool boxes.
When we got the trailer into Rob's shop, we raised it to perform an interior inspection. We slept in the trailer that night because it provided much more room than our Alaskan camper.
Rob's
schedule, and the birth of his twins, prevented him from working on the
1017 project for several weeks. So, we returned to San Diego to
address house chores that had arisen during our 5 months of
travel. We returned to La Junta and found that Rob had painted
the chassis of the truck and ground off the large cast iron bed mounts
in preparation for the camper fabrication actions. Above is a
photo of the newly painted battery box and air system.
The
air system and cab lift jack.
The
previous bed mounts were removed and the chassis was painted satin
black.
The
exterior of the fuel tank was cleaned and painted as well.
The
transmission shield was removed to allow additional room for mounting a
spare tire rack. Note the dusty foot prints on the frame from me
climbing on top to measure clearances to the rear of the cab cargo
bubble.
Above
is the tongue of the trailer after the propane bottles were
removed. The tongue will be cut off to allow fabrication of the
front mount for the cabin. The item in the box is the hydraulic
pump that raises the top of the HiLo.
New
batteries were installed in the 1017, but the old battery restraint did
not fit well, so it was removed. It will be replaced with several
bars of steel and some "J" hooks to provide the battery restraints.
Kathleen
raises the cab on the 1017 in preparation for a fuel filter
change. And boy did it ever need a change!! Unlike my
1300L, this 1017 only has one filter and it was totally filled with
contamination.
A
view of the engine compartment. The vertical bar to the left of
center in the photo above is the shift lever.
The
front of the tongue was cut off with a plasma torch. Above, the
plastic pan that supports the hydraulic pump and house battery can be
seen. This area will be transformed into the battery box for 4-6
volt golf cart batteries that weigh 62 pounds each. The new box
will have to be sufficiently beefy to support that much weight.
The tongue was cut off so that the front mount would be flush with the bubble on the HiLo.
The
trailer axle was removed.
Rob's
industrial band saw was used to cut the 2x2 1/4" wall tubing that will
form the spare tire/generator rack.
One
of the tools of the trade: a plasma torch used to cut steel.
The
2x2 tubing was laid on the welding table prior to assembly into the
spare tire frame.
Assembly
of the spare tire frame is in progress. Above, the cross members
were inserted and positioned prior to tacking into place.
Cross
members were welded into place with the MIG welder.
The
band saw can make nice, clean cuts on thick material. Above, the
saw makes a square cut on the 2x2 tubing.
The
bed of the tire mount was laid on the frame for a sanity check.
While
we were working on the tire mount, one of Rob's other customers came by
with an issue on his U500. Some type of unusual air problem had
developed on the unit.
Rob
and the owner inspect the air system for issues.
While
they were addressing the air issues, I took a look around the
truck. The stock fuel tank and been replaced with this monster;
perhaps 100 gallons, maybe more.
Back
on the 1017, the foot cups and flex mounts were installed and tested
for fit prior to welding to the frame.
Several
beams were needed for the attachment of the HiLo to the 1017.
Above, one of the beams is laid-out prior to welding.
All
the fender skirts were removed from the trailer.
We
decided to re-use the stock bed mount for the HiLo. This mount is
massive and is designed to accomodate flexing in the frame during off
road driving..
The
finished beam was laid on the frame to provide visual confirmation of
the approach. Along the way, the rear fenders were removed to
provide clearance for the frame mounting hardware.
The
plasma torch creates nice fireworks when cutting ferrous metals.
Above, Rob cuts part of the stock mount to provide clearance for rivets
in the frame.
Good progress is
being made. So far, we are 3 days into the project and I am
pleased with the progress. We still have to complete the head
board for the tire mount, fabricate the tire lifting crane, complete
the mounting frame and lift the trailer onto the truck for a test
fitting. Additionally, there are a ton of external cosmetic
issues that need to be addressed as well as battery box fabrication and
all the internal modifications. A ton of work has been done, but
several tons remain.
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Photos and Text Copyright Bill Caid 2010, all rights
reserved.
For your enjoyment only, not for commercial use.