Blazer Chalet #0661

[sweetk30]

Originally Posted by LEEVON

Ugghh, sorry about the oceans of bondo. What's wrong with people!?

but but but i saw them do it in 7 days on tv . . . why cant i do this and make money ..... thats whats wrong

[lowbrow454]

Originally Posted by LEEVON

Ugghh, sorry about the oceans of bondo. What's wrong with people!?

Originally Posted by sweetk30

but but but i saw them do it in 7 days on tv . . . why cant i do this and make money ..... thats whats wrong

It gets worse. Some bad metal work under the bondo. I don't understand, if you're gonna take all that time with the bondo why not do it right?

It's really not too big of deal. We knew there was some rust and bondo and our body guy knew it too and quoted it accordingly so it's not like it's gonna be a big surprise bill. Was just surprising to see what was underneath.

Floorboards were in pretty good shape along with the bed. Fenders are more work that what they were worth, gonna have to find some take offs. Drivers door needs repaired where the old mirror used to be. Passenger door seemed to be the only good panel on it.

[lowbrow454]

Few more....

[Zoomad75]

Great progress for sure. Bummer on the hidden fun under that shiny paint, but it's getting fixed so all will be well.

I'm curious what the end game will be. I know you and the wife want to use it for camping. Is that going to be full on using it off road to get to back country spots, or some milder forest roads and the like?

Any plans of beefing up suspension/axles for durability and strength? Not saying going nuts for a D60/14bff combo, but 3/4ton axles at least. I think a 14bff would be indestructible under your setup and just adding 8 lug hubs to match on the D44 up front.

Good work again.

[lowbrow454]

Originally Posted by Zoomad75

Great progress for sure. Bummer on the hidden fun under that shiny paint, but it's getting fixed so all will be well.

I'm curious what the end game will be. I know you and the wife want to use it for camping. Is that going to be full on using it off road to get to back country spots, or some milder forest roads and the like?

Any plans of beefing up suspension/axles for durability and strength? Not saying going nuts for a D60/14bff combo, but 3/4ton axles at least. I think a 14bff would be indestructible under your setup and just adding 8 lug hubs to match on the D44 up front.

Good work again.

So the end game is probably a little more on the mild side but still want to get into some back country spots. Nothing too out of control where it will get torn up but definitely off the beaten path. We also would like to do some road trips in it and some car shows. Nothing fancy or trying to win anything, just fun to show off. It's different and loud with the orange so it should be fun. When we first got it right before we started tearing it apart we went to a small local show. My wife and mom set up the inside, she had lots of fun with that and wanted to do more stuff like that.

The 3/4 axles we have talked about. It's on the list for the future but probably will be down the road. You're right it would be a really good setup.

Here's some pics from the show.

[Zoomad75]

That's a good plan. I've always thought the Chalet's were a little too big to really go far off the beaten path like I do with my FWC camper. (which gets called a Chalet A LOT). I wouldn't want to put that fiberglass through the abuse I've stuck mine into this last year. (I've got a pine branch still on the roof rack from our snow run on new years day too)

The real chalet's like yours need to be preserved, used but not beat to death. I've followed a few threads where they got built up and then yanked off and set in a pasture somewhere. Kudo's for actually going through the effort to restore one.

I like the plate # too. Nice touch.

[lowbrow454]

Originally Posted by Zoomad75

That's a good plan. I've always thought the Chalet's were a little too big to really go far off the beaten path like I do with my FWC camper. (which gets called a Chalet A LOT). I wouldn't want to put that fiberglass through the abuse I've stuck mine into this last year. (I've got a pine branch still on the roof rack from our snow run on new years day too)

The real chalet's like yours need to be preserved, used but not beat to death. I've followed a few threads where they got built up and then yanked off and set in a pasture somewhere. Kudo's for actually going through the effort to restore one.

I like the plate # too. Nice touch.

Thanks! I would love to have something like yours that's not so tall. You got a pretty cool set up.

[Zoomad75]

Originally Posted by lowbrow454

Thanks! I would love to have something like yours that's not so tall. You got a pretty cool set up.

Thanks!

I would sure like the height you got with the top popped up. I'm pretty tall so with the top up on my FWC I'm brushing the roof with my head. Sleeping in the cabover section on mine is comfy with the right mattress, but It's still to short to sit upright up there. I'll fix both issues when I redo the canvas. I'll just add a few inches.

I'm pretty darn careful off road now. Out in the desert where there aren't many trees, it's pretty easy. The mountains near me are a different story. Tree pinstriping is a given. But narrow jeep trails gain a whole other level of fun. I've got to replace the window screens on the passenger side from all the tree branches I've brushed up against this summer.

[lowbrow454]

I know what you mean. When I dropped it off to the body shop the guy was talking about the basecoat/clearcoat and mirror finish while the whole time I'm thinking in my head, I don't want to hear how nice it's going to be and then all the scratches I'm gonna put on it. Made me cringe a little inside.

[Zoomad75]

Lots of clear my man. If Larry's k10 is any example I've seen, it's a good layer of clear. He and I have been down many of the same trails together and hit the same branches. He's polished it out a couple of times and it's still pretty sharp and it was painted over 15 years ago by a buddy of ours.

The idea is not to scratch it, but many times it's not avoidable. Best thing is to go slow and try to keep an eye on both sides. I've learned on some of the tighter trails to also watch which way the trail slopes. I've had to tread the needle between two trees but the trail sloped from left down to the right. Had I cheated more the the right the slope would have caused the roof of the camper to hit the tree on the right since the tilt pushed the roof over further at the top. So I hug the inside tree close on the uphill side sine the tilt puts me away from it and still have room to clear the downhill side.

I won't lie, it can be nerve racking. But it helps if your passenger keeps an eye out too.

[dagnabbitt]

Beautiful truck, beautiful job you are doing with it. I need a Chalet, I have decided.

[lowbrow454]

Originally Posted by Zoomad75

Lots of clear my man. If Larry's k10 is any example I've seen, it's a good layer of clear. He and I have been down many of the same trails together and hit the same branches. He's polished it out a couple of times and it's still pretty sharp and it was painted over 15 years ago by a buddy of ours.

The idea is not to scratch it, but many times it's not avoidable. Best thing is to go slow and try to keep an eye on both sides. I've learned on some of the tighter trails to also watch which way the trail slopes. I've had to tread the needle between two trees but the trail sloped from left down to the right. Had I cheated more the the right the slope would have caused the roof of the camper to hit the tree on the right since the tilt pushed the roof over further at the top. So I hug the inside tree close on the uphill side sine the tilt puts me away from it and still have room to clear the downhill side.

I won't lie, it can be nerve racking. But it helps if your passenger keeps an eye out too.

Oh for sure, you're definitely right on the clear. It's just makes me cringe a little to know it's gonna happen but I guess that's part of the fun. It will be a learning curve figuring out how to navigate through some of those trails with the camper on. Yours is a little lower but did you notice much of a difference in the way it handled on the trail after you put it on?

Originally Posted by dagnabbitt

Beautiful truck, beautiful job you are doing with it. I need a Chalet, I have decided.

Thanks! Better grab one quick. Unfortunately I've seen prices go up on them even in the short time we started looking.

[Zoomad75]

Yours is a little lower but did you notice much of a difference in the way it handled on the trail after you put it on?

Not much, but that was by design in my case. I made sure everything heavy is kept low in the body. The only heavy thing above the bed rail height is the propane tank. I eliminated the water tank, sink and stove out of the cabinet. Mainly for the weight savings, but I didn't want to deal with winterizing the water system. The stove wasn't much but it was all the way high and in such a small space I didn't want to stink up the interior cooking. I use a camp stove and it's stored under the lower bench. The 3 way fridge got yanked due to it's questionable ability and being an amp hog on 12v vs modern day 12v compressor fridges. Plus it was heavy and right in the way of my seat at the full back position.

The rebuilt cabinet was truly overbuilt with thick plywood and solid oak face boards and doors. But inside those cabinets is a tote with cooking gear and other with other gear and food.

All in all you can tell the truck has a slightly higher CG than it did before but it's not overly tippy. I put a lev-o-gauge on the dash and have put it in an upholstery sucking position a couple of times this summer, but it would have been the same with the stock top on. I play close attention to it though. In the sketchy stuff I rely on who's spotting me along with what I'm feeling inside. I've backed off and taken a different approach because it was spooky.

Your setup is probably heavier empty than mine due to the fiberglass construction vs aluminum frame and siding in mine. Your CG will be higher than mine. Try to load gear as low as you can to offset the fridge and water tanks. You won't be doing the stuff I've done, so really sketchy stuff won't be a problem. You'll get a feel for it. Everybody has a different threshold for how much tippy is too much.

What I wouldn't do is eliminate the sway bar like many do in all out off road builds. You need that bar there for the handling on road as the barn door is going to catch the wind like a sail. Off road, you don't want that truck to flex like mad with the high CG. The body will lean over and really make it tippy.

I think for your intended plans you should be ok as you are.

[lowbrow454]

Originally Posted by Zoomad75

What I wouldn't do is eliminate the sway bar like many do in all out off road builds. You need that bar there for the handling on road as the barn door is going to catch the wind like a sail. Off road, you don't want that truck to flex like mad with the high CG. The body will lean over and really make it tippy.

I think for your intended plans you should be ok as you are.

Good advice. I've been going back and forth on the sway bar and I think you are right. What I plan on doing with it the sway bar would make more sense to leave in place.

[lowbrow454]

So we are going to go with a Hickey drop style hood on the Chalet. Waiting to find an original one in good shape and getting it to Oregon was not very feasible so we got a new one from Autofab. I think this will really add to the 70's styling we are going for. I messed around with some free online paint programs to figure out a paint scheme. We think we are going with the first one but would like to know everyone else's thoughts. It wouldn't have the thin black strip that is shown in the pic. That's just my lack of paint skills.
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[Zoomad75]

Number 1 for me. Those hoods are sweet.

[Hammered 77]

I like the first one also but was wondering what it would look like with the brush guard paint the light cream instead of black.

Rick

[lowbrow454]

Back to work on the camper. Tear down of the Chalet to take in for fiberglass repair and paint.

[James Lamb]

Man seeing those pics makes me wish I still had mine. But grad school and not very much $$$ was not conducive to having an extra vehicle that got 10mpg.

FYI, if you have not discovered it yet, there's a small triangular trim piece right behind the passenger seat, accessible once you flip the seat forward. It's held on by 3 or 4 screws. There's a cavity about the size of a small shoe box behind the panel. Makes a great place to stash extra cash when traveling. Also, what with the fridge in the rear, the main power cable runs beneath the body. Mine caught on fire (the wires) amazingly enough while I was under the truck. Lots of yelling at a friend to disconnect the battery (he disconnected the wrong one first) while I was blowing, swatting, etc. Anyway, I would put those wires inside a cable sleeve, especially if you plan on doing any four wheeling in it.

[lowbrow454]

Originally Posted by James Lamb

Man seeing those pics makes me wish I still had mine. But grad school and not very much $$$ was not conducive to having an extra vehicle that got 10mpg.

FYI, if you have not discovered it yet, there's a small triangular trim piece right behind the passenger seat, accessible once you flip the seat forward. It's held on by 3 or 4 screws. There's a cavity about the size of a small shoe box behind the panel. Makes a great place to stash extra cash when traveling. Also, what with the fridge in the rear, the main power cable runs beneath the body. Mine caught on fire (the wires) amazingly enough while I was under the truck. Lots of yelling at a friend to disconnect the battery (he disconnected the wrong one first) while I was blowing, swatting, etc. Anyway, I would put those wires inside a cable sleeve, especially if you plan on doing any four wheeling in it.

I saw the panel but didn't think anything of it till you said something. Definitely a good idea.

Pretty scary catching on fire while you are working on it. None of the camper accessories have been tested yet. After we get it back we plan on going through all the wiring and plumbing. Didn't want to light the furnace after 40+ years of rotten hoses. That would be my luck to burn it down after paint.

[lowbrow454]

Door is pretty jacked up. Hopefully we can find the trim to redo the door frame. Not looking hopeful at the moment.

[James Lamb]

Those rear doors definitely a weak point. I had issues with mine too. I seem to remember there is a wood frame inside them?

FYI, I found the fridge was not tremendously efficient as far as how long it took to cool down. Not surprising I guess given it's a mid 70's design and really old now. It might be worth looking to see if it can be replaced with a newer unit. I was always too worried about fire to think of using the propane heater option, always thought if I had kept mine now that I have money I would remove some things like the heater guts and insulate the heck out if the fridge, maybe run a heavy alternator and two extra accessory batteries to power fridge. I used to be off road camping in mine for a week at a time.

Also, the interior lights I remember getting really hot - like almost burn your hand if you touched the metal reflector when you turned them off kind of hot. Would probably be well worth trying to find an led bulb for for comfort and less battery drain. I also thought that giant flat roof would be great for a solar panel to help keep batteries charged.

[lowbrow454]

Originally Posted by James Lamb

Those rear doors definitely a weak point. I had issues with mine too. I seem to remember there is a wood frame inside them?

FYI, I found the fridge was not tremendously efficient as far as how long it took to cool down. Not surprising I guess given it's a mid 70's design and really old now. It might be worth looking to see if it can be replaced with a newer unit. I was always too worried about fire to think of using the propane heater option, always thought if I had kept mine now that I have money I would remove some things like the heater guts and insulate the heck out if the fridge, maybe run a heavy alternator and two extra accessory batteries to power fridge. I used to be off road camping in mine for a week at a time.

Also, the interior lights I remember getting really hot - like almost burn your hand if you touched the metal reflector when you turned them off kind of hot. Would probably be well worth trying to find an led bulb for for comfort and less battery drain. I also thought that giant flat roof would be great for a solar panel to help keep batteries charged.

Yes the door is a wood frame with some really cheap cardboard insulation.
Gonna try and keep the fridge if possible. Trying to leave what was original to a point. Down the road we plan on building a trailer to go along with this. The chalet is great but is lacking for storage for longer than a weekend trip. Not really much will fit in the fridge and there is nowhere to store firewood, cooler, recovery gear ect...

LED's are a great idea. I can imagine with all the dark wood and those bulbs it can be a little dim inside.

[notsolo]

Nice project, looking good....Ripped is not what you want to see when looking at that door, maybe some updated waterproof building materials...Aztec pvc comes in 4'x 8' sheets, 3/8" ...1/2"...as well as 3/4" boards etc ....just a thought...Very cool shop with some interesting displays.....

[Ryan_S]

Just read the tread tip to tail. Great looking build! I'll be following along from here on out. I'll be interested to see what you come up with for the trailer. Will it be painted to match?