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Old 02-24-2016, 08:02 PM   #1
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Lightbulb '96 1005 Jay. New owner big refurbish project - advice appreciated

Hi Everyone,

New forum member here.
We are the proud (new) owners of a 1996 1005 Jay series pop-up camper.

My wife has always wanted a camper and we got this one from a friend. It has only been on a handful of trips in it's life time but the materials have been mouse eaten while in storage. So we have a major cosmetic refurbish project ahead of us (which we are looking forward to).

Before I get into fixing the cosmetics I want to tackle some safety/reliability concerns:



0) Insurance + registration MA
Am I going to run into any problems registering the trailer and getting issuance - does it need an independent inspection (yearly?) - do I need to install breaks (see below), or add some other safety features to comply with new laws ?


1) New tires
The info plate on the side of the camper lists the tire size - great.
5.3x12C (GVWR 2205 lb) I'm finding quite a few online places. any preferred brands or models of tires people recommend?

2) new rims (optional - paint peeling, some rust)
Not sure of the bolt pattern- listed as "12x4JA" rims. What rim size and bolt pattern should I be looking for ?

3)New wheel bearings / hubs
Assuming the bearings are 20 years old. Must replace. Not sure what parts to buy, the owners manual I've found doesn't list the replacement size or type. . I do not want a breakdown later this summer when we plan to drive it from MA to Maryland.

Does anyone have suggestions of the correct bearing part? I'm happy to replace hubs+ bearings if that is easier re-work. Anything else I should look at replacing or greasing / maintenance while I'm working under there.

4) Sway bar
From what I see it has no break system. I'm OK with this, and on a friends advise purchased a sway bar kit that I plan to install to improve safety/handeling. Any comments/ suggestions for install / driving with a sway bar?

Cosmetics ( I'll be sure to post our before and after pictures )
5) New canvas
Any suggestions for a new canvas vendor? We've found some online but would appreciate anyone's feedback on which are good quality / easy to install.

6) Paint outside
I've seen some great guides/suggestions here. We're going to do something "cool"

7) Solar
Got a 100W solar panel, charger, batteries, fuses, and 12V LED lighting so should be all set for that project. I'll be sure to share my solutions here.

8) Cabinet and interior surface rework
Again some great guides here and my wife already has a pintrest full of ideas.

Many thanks in advance.
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Old 02-24-2016, 08:05 PM   #2
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I've attached a picture of the "project" here. The dead mice are now removed and the inside is quite clean.
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Old 03-28-2016, 10:34 PM   #3
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Hello and welcome Nemi!

So many questions and so little time haha. Let me see if I can give you some background before I attempt to answer some Q's.

I bought a 1994 Jayco 1207 that turned out to be in pretty poor condition all the way around, I was new to trailers and didn't know anything. I scoured threads such as this and another big name one, and found so much help and info! My restoration is complete as of the end of 2015 and already have 18 days camping this year!

Ok, now let me see if I can be of any help to you...

0) Registering my PUP was a snap at $14 per year, however it is annoying that because it is considered "livable" I cannot get permenant tags. I did opt to insure mine as it only added like $20 per year to my multi vehicle policy

1) I went to Big O tires and bought the cheapie tires as I don't plan on long tow trips. My preferred campground and lake is only 80 miles from home

2) Because I was able to tow the entire trailer to Big O tires they were able to determine what exactly I needed. Maybe remove a tire and rim and take to local tire shop so you ensure correct size? As for my rims I simply sanded them down and used some good ol Rattle cans of Rustoleum paint!

3) My most expensive replacement was my axle as the bearings had never been serviced and the previous owner towed it beyond repair. It was extremely simple to put trailer on jack stands and pull entire axle off. Again I took it to an axle dealer for their professional replacement recommendation. They advised that I upgrade the weight capacity of the axle while I was doing it, and for an extra $30 I was able to get a heavier duty axle (more weight capability)

4) SWAY BAR WAS A MUST FOR ME!! I cannot tell you how much of a difference it made in the towing experience. Best $40 upgrade I have done so far!

5) I decided to ride out my canvas for as long as possible, but I did do some research and decided on Bear Creek Canvas | Pop-Up Camper Recanvasing Specialists | Spencer WI for my replacement when I am ready

6) if you click my user name I believe you can see a few pictures in my user photo gallery. I did paint my PUP and because it has the "orange peel" type of aluminum siding I felt comfortable using a brush and roller. Paint has been on over a year now and looks brand new still! Good ol Rustoleum haha. Oh I used Robot Check to remove the pinstriping, worked like a charm!!

8) I found an amazing primer that sticks to the cabinet wood type contact paper so I could paint and refinish the interior Zinsser Bulls Eye 1-2-3 1 gal. White Water Based Interior/Exterior Primer and Sealer-2001 - The Home Depot this stuff is so incredible!! It made the interior refurbishing a pleasure!

Wow, this was a lot! If I can be of any help or even just a sounding board, please reach out. Even if you would like some more pictures. Good luck on your project!
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Old 03-29-2016, 05:50 PM   #4
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Spencerteri,

thank you very much for all the info.

A couple of weeks ago I cut out the canvas to start work on the inside more easily. Unfortunately the PUP stuck in the up position. the nylon pulley guiding the two cables tot he rear had disintegrated and trapped one of the cables - I had to cut it.

Now looking drilling out the pulley, replacing with metal one and *maybe* splicing the cable back together again. I'm only seeing sets of 4 cables online, not single ones - any ideas for single cable suppliers?

Our auto ins. agent is going to help us with registration.

We found this deal on canvas:
1997 Jayco 1005, 1006, or 1007 camper canvas | RV Workshop
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Old 03-29-2016, 06:19 PM   #5
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When we had a popup we purchased new canvas from Bear Creek Canvas and it was perfect. Ours was a very old popup so we had to take the old canvas off and send it to them to use as a pattern. The new canvas fit perfectly and was easy to install.
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Old 04-02-2016, 07:58 PM   #6
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Thanks for your vote of confidence in Bear Creek. I have only heard of good things about them!
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Old 04-02-2016, 08:02 PM   #7
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Quote:
Originally Posted by nemi View Post
Spencerteri,

thank you very much for all the info.

A couple of weeks ago I cut out the canvas to start work on the inside more easily. Unfortunately the PUP stuck in the up position. the nylon pulley guiding the two cables tot he rear had disintegrated and trapped one of the cables - I had to cut it.

Now looking drilling out the pulley, replacing with metal one and *maybe* splicing the cable back together again. I'm only seeing sets of 4 cables online, not single ones - any ideas for single cable suppliers?

Our auto ins. agent is going to help us with registration.

We found this deal on canvas:
1997 Jayco 1005, 1006, or 1007 camper canvas | RV Workshop
Nemi,

Fortunately I haven't had any experience with the lift system. However I have seen many posts in this forum as well as the other forum I use popupportal.com

I would reccomend reading about canvas replacement experiences in forums, as everyone I have seen about Bear Creek is Ultra Positive!
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Old 04-02-2016, 09:13 PM   #8
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X2 Bear Creek Canvas is the place to go for replacement canvas. Also lots of great information both here and on Popupportal.com for your restoration project.
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Old 04-03-2016, 07:33 PM   #9
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Great job bringing her back to life! I follow "the pop up princess" on instagram because the picures of people's pop up remodels are amazing. What's the next project?
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Old 04-05-2016, 03:24 AM   #10
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When we had our pop-up the lift system was also broken. Instead of only buying replacement parts from RV suppliers, my husband bought some things (cables and a crimper) at Lowes. They were cheaper and we only had to buy what we needed, not a whole "set."
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Old 05-30-2016, 12:10 AM   #11
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Cable

Quote:
Originally Posted by nemi View Post
Spencerteri,

thank you very much for all the info.

A couple of weeks ago I cut out the canvas to start work on the inside more easily. Unfortunately the PUP stuck in the up position. the nylon pulley guiding the two cables tot he rear had disintegrated and trapped one of the cables - I had to cut it.

Now looking drilling out the pulley, replacing with metal one and *maybe* splicing the cable back together again. I'm only seeing sets of 4 cables online, not single ones - any ideas for single cable suppliers?

Our auto ins. agent is going to help us with registration.

We found this deal on canvas:
1997 Jayco 1005, 1006, or 1007 camper canvas | RV Workshop
I bought 3/32 cable at Lowe's. 4.80 for 16'for back right opp of door.
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Old 05-30-2016, 12:14 AM   #12
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Do you have any pics/info about the lower door? What should fill the gap between ? I have a 95 eagle 8. I am guessing that the top and bottom should open and close together.
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Old 06-14-2016, 05:10 PM   #13
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I am sold on Bear Creek.. That is where ours came from and it is a 100% improvement in both quality, constuction and appearance.
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Old 08-07-2016, 04:45 PM   #14
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It's done!



After many weekend hard work (DIY) the refurbishment is complete! Thank you to everyone for your advice.

We striped out the old canvas and replaced with one from canvasreplacements.com.

New tires and wheel bearings

Extra amber and red reflectors and extra set of LED brake/indicator/running lights at rear

Removed a few 10's of dead mice and a few thousand mice droppings.
disinfected inside.

Stripped off old wood veneer, used exterior paint and made more modern. Fresh paint everywhere inside.

Replaced the rusted out brass fasteners with SS or zinc dipped screws.

replaced interior lights with LED (lower current) and added LED strip light above range.

(will replace all exterior lights with LED bulbs later in year)

Propane lines tested (good)

Main Lift eye bolts replaced and one of the pullys replaced with steel one

New stick on laminate covers for work tops and tables

All plastic/ metal trim / handles removed and resprayed, including support bars

100W solar system and 4x 7Ah battery storage with charge controller and DCAC inverter

roof cleaned of algae, filled/ sealed and painted with exterior paint (sides to do next spring)

made a new trailer electrical cable to the SUV

Soaked / Cleaned out the old foam bed and seat bases. Made new covers for everything.

Put in deep-pile stain-resistant carpet (removable and washable)

(Sway bar goes in this week)
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20160807_144834.jpg   20160807_144108.jpg   20160807_144910.jpg   20160807_165554.jpg   20160730_094640.jpg  

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Old 08-07-2016, 04:47 PM   #15
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before

here are the before pictures
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20151107_152640.jpg   20151114_155140.jpg   20160319_155010.jpg   20160417_120604.jpg   20160417_125851.jpg  

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Old 08-07-2016, 04:50 PM   #16
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solar system

If anyone's interested, here is the solar / battery system I designed.

I used multiple 7Ah SLA batteries (as that is what I have to hand in my UPS systems at home)

The system support 2 differnt modes:

1) off grid use , solar charges batteries, solar controller provides regulated 12V power, inverter for AC (400W).

OR

2) AC hook-up - trickle charger tops up batteries, and ACDC 12V 2 amp supply runs the LED lighting.
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20160805_195307.jpg   20160805_195212.jpg   Untitled.jpg   Untitled2.jpg  
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Old 08-07-2016, 04:57 PM   #17
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Wow

Amazing job. It looks really nice and airy inside. Maybe Jayco should hire your family for interior design.

Enjoy your "new" trailer, you've earned it.


P.S. Like the design mod to your pool as well.
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Old 08-07-2016, 06:32 PM   #18
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Absolutely Amazing

Great job!

Pat yourself on the back for a job well done! I hope you and yours enjoy your "New PUP" as much as we do. It looks fantastic :-)
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Old 08-07-2016, 06:39 PM   #19
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Doors close together

Quote:
Originally Posted by Indy_jonz View Post
Do you have any pics/info about the lower door? What should fill the gap between ? I have a 95 eagle 8. I am guessing that the top and bottom should open and close together.
Indy,

I just saw our question, am I correct in understanding you want to know how the top and bottom door attach together, so they act as one?

If so, on my PUP the top door has a down facing U track that sits on the top of the bottom door. This acts as a joiner, and makes them function together.

The PuP is stored till our next trip in October, so I cannot get any pics for you.

Hope this helped,
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