M1102 / Gichner S-250 Comms Shelter Camper

[Phoenix77]

I bought a Gichner Systems S-250 Comms Shelter on GovPlanet with the idea of converting it to a micro camper for me, my wife, and my 12 y/o daughter. I decided on an M1102 trailer as the host, as I have a 1986 AM General M998 HMMWV, and it would ride appropriately, and also my Tacoma TRD Off-Road would pull it easily.

Here is the shelter I started with:

 

[Phoenix77]

Next, I bought an M1102 trailer up in MD from GovPlanet a couple weeks later from a big lot of M1101 & M1102 trailers for sale and had it hauled down to me.

 

[Phoenix77]

I stripped out everything from the S-250 and saved all the fasteners, wiring, radio racks (which I later sold on eBay), power source etc. and stored in a big Hardigg for repurposing. The fans still worked, but they are 26.5v, which obviously wasn't going to work with the 12v system I planned, so they were later swapped out for 12v radiator fans.

 

[Phoenix77]

After stripping everything out, my daughter and I washed the inside with soap and water (there is a convenient floor drain).

In the interest of this being a father-daughter project, we went to Lowe's and I let her pick out the paint colors. The theme is milsurp exterior, cozy, vibrant and upscale interior. I spray painted the ceiling blue, then we painted the walls together.

 

[Phoenix77]

The shelter weighs ~760 lbs, and as I was unable to lift that with my tractor, we got creative by using one of the trees on our 9.5 acres to Jerry rig a hoist to lower the shelter into the M1102 trailer.

 

[Phoenix77]

With the S-250 in the M1102, work continued. Initially I was thinking I would paint the shelter and the trailer a single, solid OD Green, but I love camo too much to paint over it (I know, I have a problem).

I decided to freshen up the paint on the trailer and go with a satin OD-ish green so I could get some heat reflection from the aluminum to help with cooling.

I did the cut out for and installed an RV window - real pucker factor taking a sawsall to a perfectly water tight vessel and rolling the dice I wouldn't mess it up. I also bought a bunch of angle steel to fabricate gypsy racks like big erector sets with repurposed 3/8" bolts & nuts on the corners. You can see some of the wiring from lights coming out of the shelter to where I would later install the power box.

 

[Phoenix77]

I used a surplus watertight storage box as a power supply center and mounted it outside, as space is at a premium inside. I have a heavy duty car battery, then the guts from a repurposed old RV power panel with converter and breaker bar etc. I also installed a solar vent fan on top to help ventilate the components.

I installed a 200w solar array on the roof, which charges the battery. I later wired a 110v outlet inside and ran the 30A shore power cable out from the power box.

 

[Phoenix77]

Back to the interior.

I built a cabinet using materials I had in my woodshop (3/4" ply for the carcass, as it was going to support the top bunk).

I used surplus laminate flooring from building our house and extended the bunks out to 24" using 3/4" ply. I cut a king size 6" ultra plush memory foam mattress into three (3) pieces using a sawsall and two (2) clamped 2x4s as a guide. We have three (3) super comfortable bunks for a total of $160 from Amazon. I decided to do the mattress retaining trim out of cherry (I build furniture as a serious hobby).

I also repurposed a heavy post support that was installed in the M1102 and a fitting from the small air vent in the side of the shelter, added a piece of PVC as a vertical member, then fitted it all together with the cherry and purple heart table top I made. It breaks down and can be stowed easily.

I installed a second RV window on the right side to make it feel bigger. All wiring complete here, with a couple multi-gang switch panels to operate exterior lights, vent fans, and control power to the two (2) dual USB charging ports. You can see the 110v outlet on the right.

 

[Phoenix77]

Exterior with multiple gypsy racks installed for water / cooler, and a few 5 gallon Jerry cans. Bought a surplus vehicle ladder off eBay and used angle steel leftovers to secure it to the tailgate via hitch pins.

Wanting more real estate off the back, I rigged a pull-out deck utilizing M105 trailer tailgates bolted together, held up by 2.5" angle steel brackets and a positive stop to avoid complete deployment onto the ground. A pair of M105 adjustable legs support the weight of the extended deck.

I ended up getting a lot of six (6) M105 tailgates from MECO on eBay for $400 shipped. I needed three (3) for the deck, so I used two (2) as deployable side counter space / seating. I used door hinges to secure them, so if I need to access the wheels / tires, I can knock out the hinge pins and remove them easily.

Also cut a third hole and installed the A/C unit.

 

[Phoenix77]

I made screens for the original hatch openings with teak frames that mount via carriage bolt & wing nut. I remove the screens and have a set of toggles that hold the hatches shut from the inside for security purposes.

We visited our friends who have a traditional camper at a campground over Memorial Day weekend and I saw all the high end campers / RVs had undercarriage lights, so not to be outdone, I added them to ours for $28.

I used a surplus computer server case as a deployable gas grill housing. I used 100lb full-extension ball bearing glides and made the shelf like a cutting board out of cherry, maple, zebrawood, and Shedua, then mounted the assembly to the front of the trailer. Still plenty of room for turning when towing with the Tacoma.

 

[Phoenix77]

Aside from rain, a pretty successful first outing with it. It is primarily meant for overland camping and SHTF (it flood in eastern NC) or camping on the beach, but I am really pleased overall.

We had a composting toilet for those needs, and if overland camping, have a 5 gallon sun shower.

 

[tennmogger]

That is an inspiring build! Thanks for sharing it.

 

[Tow4]

Wow, very nice build!

 

[Phoenix77]

Thanks; it was a fun project. Having my wife begrudgingly admit it was nice and comfortable was almost as great as working on it with my daughter.

 

[lfhoward]

Freakin’ Awesome. Really nice work!

 

[BirdieChain]

Freakin’ Awesome. Really nice work!

Agree you have what I will be trying to create with my M1102 and 13' slide in truck camper. Getting my 26 year old daughter involved maybe; her saying it's comfy on a cool night in the Sierra someday.
"Priceless"

 

[flyfishtrailer]

Very nice job

 

[Phoenix77]

Thanks everyone. This build is now for sale: $8,000 OBO

 

[Pat Gray]

GREAT JOB!!!

 

[JD4044M]

Well done and use of the outside is a plus! Were you able to license it? That is one thing I wondered about Military Trailers one day I want one for my M1078 for hauling more hay in one load.