Project 2004 16.49-1 Modernisation

[Mike Jamieson]

I had been looking for a new or newish Jayco for some time. But then the expense of having 100k sitting around most of the year didn't make alot if sence. Then I stumbled across this forum. I found a thread from Moto and got the brain thinking. Why not do that? Buy an older caravan and modernise it.
So I found a 2004 expanda in good condition and now we are into it.
It already had solar installed, axel flip, and a few other mods.
I'll post up some pics and progess as we go.
Here she is in her as bought form.
My business is a bit quiet so it will be all hands on deck next week to upgrade her.
Remove decals and vinyl front
Raptor coat front and lower sides
New wheels, tires
Get electric brakes working
New front toolbox with bbq pullout
New exterior hatches and vent covers
New jockey wheel
Off road hitch with drawbar extension
Rear drop down or swing out tire carrier
Add alloy bonnets front and rear similar to new jayco expandas
Led light upgrade
Electrical upgrade
Plumbing upgrade
New table
Carpet
Underbody seal
Mudguards
reseal roof.

Yep it's a big list, but we are into it!

 

[Mike Jamieson]

Got rid of the ugly front and rear travel covers it came with.
Got most of the decal removal done.
About 4 hours to removed them all.
Used hot water from a boiled jug. Poor over decal and start peeling. Keep pouring the hot water on as it lifts. It softens the vinyl allowing it and the glue to come away fairly easily. Cleaned up with brake cleaner. I'll get a buffer to blend in the rest

 

[Mike Jamieson]

New wheels on.
Painted up the hubs as well.
Tire size I went with is 235/75/15. They are a pretty tight fit but there is enough clearance all round. Couldn't go any larger without moving the steel framing.
Axel is underslung under leaf springs but not rotated. So axel stubs are on top of the axel beam. It could be rotated around as Moto has done to give another 100mm of lift - approximately.
Standard Wheel off set is 12p. 114.3 mm 5 std 14 inch rims - old falcon holden pattern.

Removed the yuk colour front vinyl. Cleaned off the glue with paint thinners and resealed with bond and seal.
Raptor coat next.

New Jockey wheel on.

 

[chartrock]

Wow, you sure have taken on something although there did not appear much wrong with it in its original form. That is some workshop you have as well.
Welcome to the forum, you will get plenty of verbal assistance with any questions. Good luck with the project.

 

[Drover]

First post, pics and all, certainly on a winner, welcome to the mob .............. Perfect type pf project when you have somewhere decent to work, sounds like off set axle, I reckon you know but don't forget the brakes/hubs must keep the same aspect or they won't work top and bottom as well as left and right................... changing backing plates is a pain ..... If I wanted a bit more height I would chuck the off set and get a new 50mm square straight axle they have a higher load rating as well..
Looking forward to your progress reports..................... GR8 stuff.

 

[Mike Jamieson]

First post, pics and all, certainly on a winner, welcome to the mob .............. Perfect type pf project when you have somewhere decent to work, sounds like off set axle, I reckon you know but don't forget the brakes/hubs must keep the same aspect or they won't work top and bottom as well as left and right................... changing backing plates is a pain ..... If I wanted a bit more height I would chuck it and get a new 50mm square straight axle they have a higher load rating as well..
Looking forward to your progress reports..................... GR8 stuff.

Thanks, I didn't realise the brakes needed same aspect top bottom or left and right orientation.
Probably keep as is unless I get rubbing or put a packer and longer u bolt if I need more height.

 

[Mike Jamieson]

New grab handles.

 

[Mike Jamieson]

All prepped up ready for raptor coat tomorrow.
Broke the wheel arch surrounds removing them so looks like new custom ones added to the list.

 

[Drover]

The brakes have a hand brake lever which only works one way as well as a magnet which must be in right position, the backing plate bolts only go one way......... If on your off set axle the main axle is under the springs with the stub axle inline with the spring pack then it has probably been moved already as I think, not 100% certain but often the axle shaft wpuld be on top of the spring with the stub higher again being 50mm above the spring pack...... see how it sits and handles when your done to see if it needs something done to it.

The wheel arch skirts are easily replaced with the usual wheel arch flares for cars and probably last longer..............

I would give the roof a good scrub, remove any crappy sealant and reseal then slap some of that roof heat shield paint over it all, seems to do a good job, we did the roof of a mates motorhome a couple of years ago and it lives outside and has handled the QLD sun very well, no shrinkage or cracks......

I would love to be able to give my rig a spray job, mate had the perfect shed for it and he goes sell it to downsize, think he's sorry now with no shed....

 

[1DayIll]

I had been looking for a new or newish Jayco for some time. But then the expense of having 100k sitting around most of the year didn't make alot if sence. Then I stumbled across this forum. I found a thread from Moto and got the brain thinking. Why not do that? Buy an older caravan and modernise it.
So I found a 2004 expanda in good condition and now we are into it.
It already had solar installed, axel flip, and a few other mods.
I'll post up some pics and progess as we go.
Here she is in her as bought form.
My business is a bit quiet so it will be all hands on deck next week to upgrade her.
Remove decals and vinyl front
Raptor coat front and lower sides
New wheels, tires
Get electric brakes working
New front toolbox with bbq pullout
New exterior hatches and vent covers
New jockey wheel
Off road hitch with drawbar extension
Rear drop down or swing out tire carrier
Add alloy bonnets front and rear similar to new jayco expandas
Led light upgrade
Electrical upgrade
Plumbing upgrade
New table
Carpet
Underbody seal
Mudguards
reseal roof.

Yep it's a big list, but we are into it!

OK I have a later version, 2008 and will be watching with great interest to see what you do.

 

[1DayIll]

All prepped up ready for raptor coat tomorrow.
Broke the wheel arch surrounds removing them so looks like new custom ones added to the list.

Looking forward to this. Is it very expensive to do?

 

[Mike Jamieson]

The brakes have a hand brake lever which only works one way as well as a magnet which must be in right position, the backing plate bolts only go one way......... If on your off set axle the main axle is under the springs with the stub axle inline with the spring pack then it has probably been moved already as I think, not 100% certain but often the axle shaft wpuld be on top of the spring with the stub higher again being 50mm above the spring pack...... see how it sits and handles when your done to see if it needs something done to it.

The wheel arch skirts are easily replaced with the usual wheel arch flares for cars and probably last longer..............

I would give the roof a good scrub, remove any crappy sealant and reseal then slap some of that roof heat shield paint over it all, seems to do a good job, we did the roof of a mates motorhome a couple of years ago and it lives outside and has handled the QLD sun very well, no shrinkage or cracks......

I would love to be able to give my rig a spray job, mate had the perfect shed for it and he

goes sell it to downsize, think he's sorry now with no shed....

Thanks for the brake info. Electric brakes are new to me. What's the roof product your mate used? The white silicon one?

 

[Mike Jamieson]

Looking forward to this. Is it very expensive to do?

Kit was about 500 nz for 4 liters. Had a little left over, I sprayed on pretty thick as ill be towing it behind my 4wd.

 

[Mike Jamieson]

A couple pics of the raptor done.
Put most of the hatches back today. Will take some pics of them when I've got them all installed.
Prep for the raptor took about 4 hours.
Remove all hatches, wipe down with thinners, lightly sand with 240 grit, wipe down with thinners again, mask up and spray away.

 

[Drover]

What's the roof product your mate used? T

I posted a pic of the can , I'll see if I can find it................... in luck found it ......................./

I'm doing my brakes at the moment, replacing magnets and shoes, I pull them off at least every 12mths give them a clean and repack bearings, mine does about 10-15K kms a year, this year not so much, luckily only 6K as the magnets are not looking good............ only repack bearings as have to pull the whole hub off and think while everything is off everything gets done..... not one of my favourite jobs especially when away so like it all to be hunky dory.

Rigs coming on good, some Green and Gold pin striping and she'll be apples.................

 

[Mike Jamieson]

I posted a pic of the can , I'll see if I can find it................... in luck found it ......................./View attachment 68754

I'm doing my brakes at the moment, replacing magnets and shoes, I pull them off at least every 12mths give them a clean and repack bearings, mine does about 10-15K kms a year, this year not so much, luckily only 6K as the magnets are not looking good............ only repack bearings as have to pull the whole hub off and think while everything is off everything gets done..... not one of my favourite jobs especially when away so like it all to be hunky dory.

Rigs coming on good, some Green and Gold pin striping and she'll be apples.................

 

[Mike Jamieson]

Thanks for that, I'll see if I can find that product here.

That's big kms! But I guess your in the big country.
Be lucky to do 1000km here a year.

 

[Boots in Action]

Thanks for the brake info. Electric brakes are new to me. What's the roof product your mate used? The white silicon one?

Hi @Mike Jamieson , I used Sellys white polyurethane adhesive sealer. Tougher than ordinary silicon, great flexibility, east to apply, dries in 70 minutes, and clean up smooth off with turps. Handles the uv rays well and sticks like s%#t to a blanket. Might be worth a try or a lookie at.

 

[Mike Jamieson]

Wheel arch surrounds ' spats' on today.
Have to shift grey water dump pipe tomorrow to fit mubflaps.

 

[Mike Jamieson]

New black hatches fixed in. Just waiting on black water filler and fridge vents to finish it off.
Fitted new awning locks.
I thought the old locks must have been missing a tab or spring to hold them open. When I got the new ones I realized that's just how they are. So I fitted them on the opposite side so they stay open until flipping them up to lock them in place.