JayCo Popup Rebuild (Pictures)

Discussion in 'Camper Restoration Projects' started by DFire2, Jun 20, 2016.

  1. DFire2

    DFire2 Active Member

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    So my wife and I were given a bit beat-up JayCo Eagle popup camper. We don't know what the year, title just says JayCo popup camper.

    PS. At the time of this posting, we are currently already down to the studs and flooring removed, so pictures may be out of date order...

    This is what we want to do...
    + New cushion covers
    + New valances
    + New vinyl floor
    + New paneling
    + New 120VAC and 12VDC wiring and circuits
    + Remove propane lines (won't need them)
    + Remove water system (will just run off 6gal tank under sink)
    + Clean and repair, possibly if needed, replace the canvas
    + Change out ceiling lights
    + Add solar
    + Add new jacks (old ones are rusted very badly)
    + Bend bumper back to normal (looks like someone backed into tree)
    + Replace/repair roof lift system (currently RAD pneumatic lift system)
    + Remove exteriors stickers and decals
    + Repaint exterior and add decals
    + Remove and rebuild cabinets
    + Reroute wiring inside of walls through studs
    + Reseal exterior corners

    ...and many more.

    Here are some photos before demolition...

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    Let's get started!

    Cabinets go bye bye! (didn't take many pictures of this part as I was removing exterior decals while wife was removing cabinets)

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    Paneling go bye bye! Wheel wells are a pain!

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    Time to tear up the flooring, then to sanding the leftover panel glue from the studs.

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    It's getting a bit more roomy in here...

    Drilled new wiring holes...5/8"

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    Remove exterior decals...

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    Plug up some of the holes from removed propane and water...

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    We had to spray some KILZ on the aluminum backing because it had started to mold and mildew, mostly due to the rotted corner pictured. Replaced the corner and resealed it.

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    The original layout, or at least very close...

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    The new layout...just flipped around

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    My color-coded layout diagram...

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    Also to note, I went to school for CADD (computer drafting) so decided to make a simple visual of the cabinet layout...

    (a bare bones layout drawing)
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    (added cabinet walls)
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    ...and we're still going...
     
    AlexVanEks, PopUpSteve and rcc like this.
  2. Dubbya

    Dubbya Wherever you go, there you are...

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    Loving this! Been there, done that myself so I think I'll stick around and offer some encouragement as I follow your progress. [8D]

    Go ahead and click on the camera under my username to see the links to my resto and mod threads. I'm sure you'll find a few helpful ideas there. If you have any questions, just ask! I'm happy to help in any way I can. [:D]
     
  3. DFire2

    DFire2 Active Member

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    I modified the OP to show a few images a forgot. Thanks for the encouragement!
     
  4. Katskamper

    Katskamper Active Member

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    you are ambitious!
     
  5. edh

    edh Active Member

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    Thanks for posting, looking forward to more pics as the work continues.
     
  6. DFire2

    DFire2 Active Member

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    Somehow when I measured for flooring, originally I measured 6'x12' exactly. Then got it cut and somehow now it's 6'9"x12' instead. Grrr, guess I'll try and conceal that 9" worth of exposed plywood under a cabinet.

    Sent from my LG-VS980 using Tapatalk
     
  7. RFryer

    RFryer Hopkinton, MA

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    I feel your pain on that one! [:(!]
     
  8. Dubbya

    Dubbya Wherever you go, there you are...

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    well, if they cut it at the store, take your receipt and the material back and get another piece.
     
  9. DFire2

    DFire2 Active Member

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    Was thinking that, but it's only 9". Should be able to cover it with cabinets. Besides, I'd have to match the pattern, too.

    Update! Wife and I started to remove one half of the lift system so we can get the flooring in.

    Put 2x4's in next to the lift system so we can loosen it.

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    We broke every bolt holding the lift system to the floor...10 bolts for the one side.

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  10. Dubbya

    Dubbya Wherever you go, there you are...

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    Yep, that'll happen. [;)]
     
  11. Rhconcepts

    Rhconcepts Active Member

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    Well it looks like you got a great project to work on, I don't see any wood rot :) keep the pictures coming.
     
  12. HackFamily

    HackFamily Member

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    This is amazing! You are doing a fantastic job at taking great pictures.
     
  13. DFire2

    DFire2 Active Member

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    Bought some CLR and a variety pack of wire wheels, gonna try and shine up the lift tracks a bit, then paint them to look good.
     
  14. Dubbya

    Dubbya Wherever you go, there you are...

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    You don't need to use CLR on them.

    Just use the wire wheels and some sandpaper if required, wipe them down with Varsol to remove any grease or contaminants and spray on some Rustoleum. [8D]
     
  15. DFire2

    DFire2 Active Member

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    So wife and I got a lot done today...

    Grinding the rust off the tracks, at least mostly

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    ...then painted them, loved this color of brown.

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    Wife took off the top vent and painted the parts...

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    Came out real nice...and she also cleaned the ceiling :)

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    I finally got some time to work on the back of the popup, getting the plywood cut for the tail light support, still have to make one to put above it for the others.

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    Next up, finishing the back end, then hopefully the flooring sometime soon, then electrical, and paneling, and then some...
     
    AlexVanEks likes this.
  16. DFire2

    DFire2 Active Member

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    Ok, so today DW and I got the rest of the lift system removed, including the crank and winch, only broke half the bolts this time :)

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    DW put the lights and fixtures back up after cleaning the ceiling, with help from her "taller half" ;)

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    I finished my work on the back end of the PUP, now there is good support for all SEVEN lights and also the spare tire bracket (which will probably get bolted on tomorrow)

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    Oh! This is the colors we are going to paint...

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  17. The KSassie

    The KSassie New Member

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    Can't believe all the progress we've made so far! Can't wait to get the flooring in soon!!! Thanks for being my "taller half"! <3
     
    AlexVanEks likes this.
  18. Don_D

    Don_D I'd rather be camping!

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    Awesome progress, you picked an ambitious project but I love seeing how these turn out and the customization's along the way. It has much less water damage than I would have expected. Thanks for posting all the pics!
     
  19. DFire2

    DFire2 Active Member

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    Yeah, the water damage was actually quite minimal. Only lightly in the corners where the caulk seals had become weak. I still have to reseal some of those.

    We found the exact paint coat at Home Depot, $30/gal. Will need about 3-4 4x8 panels to do the walls. That's after I get the electrical run and flooring down. I might have to move the electrical outlet in the wall though...

    Sent from my LG-VS980 using Tapatalk
     
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  20. chrisxs5

    chrisxs5 Test

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    Just following, keep up the good work.
     

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