Our first trip to San Elijo State Beach, CA after the RV and truck were detailed.
After years of looking and deliberating, we finally pulled the trigger on purchasing a toy hauler. Ultimately we went with a used, well maintained unit that could use some updates, and the price had to be low enough for us to simply purchase it outright. Weekend Warrior was the brand that catapulted the segment into existence, and Eric had experience with them from the early 2000’s when they were new to the market. They were overbuilt at the time, and designed for desert dry camping with off road toys, in comfort. Seeing as those are some of our primary use criteria, it made sense to seek an RV that could deliver to those ends.
At this point, I can hear you asking yourself: you bought a really old RV, do you know the problems that come along with that? Yes indeed, RVs in general are built very quickly with not much attention to detail. This is a 2003 model, front sleeper, 26 foot. Weekend Warrior was known for a front of cabin water leak that caused varying degrees of dry rot, and this example has a small amount of cosmetic and non-structural damage. All in all, for an eighteen year old rig at time of purchase, this still has plenty of life and good memories left, especially for the price we were able to negotiate!
Selling points for this model in general are:
- 120 gallons of fresh water capacity
- 40 gallons each gray/black water tanks
- Two 30 pound (7.5 gallon) propane tanks
- Generator prep with 36 gallon fuel tank/station
- Zieman chassis with 7,000 pound axles and 12″x2″ brakes
Selling points specific to this unit:
- Honda EV6010 generator: this is a liquid cooled, two cylinder engine that supports 50 amps of total output
- Owner had meticulous maintenance records and attention to detail for operational systems of the coach, including fuel station components and awning fabric; everything worked but the bathroom vent fan and a wiring issue with the onboard charging system
- The interior had very minimal wear given the age and intended use of this style of RV
- The roof was in excellent shape
- Everything was original! Which is a plus, and why this post exists
Deficiencies we inherited overall:
- Minor dry rot damage in one part of the front storage area
- Tires at end of life by date codes, spare tire was original to 2003
- Propane tank certifications expired
- One brake drum had leaked grease onto the shoes
- Bath vent fan non-operational
- Issue with wiring/fuse for shore power battery charging
All in all, in no particular order, is our list of repairs and upgrades since we took ownership:
- New tires including spare
- New brakes, wheel bearings repacked
- Two new 30 pound propane tanks
- Two new propane tank connectors
- New propane leak detector
- New carbon monoxide detector
- Bluetooth enabled 1 DIN CD player with on/off switch hardwired in
- New kitchen faucet with dedicated filtered water spigot
- Water filter for faucet
- New shower handle/head
- Liquid soap dispenser with soap dish in shower
- New toilet with residential height and bowl dimensions
- Replace bath vent fan switch
- Repair shower curtain slides
- Repair front sleeper privacy screen
- Install solar panels and inverter
- Install cellular radio and WiFi appliance
- Service generator including timing belt and water pump
- Install analog voltage gauges for quick reference of AC and DC voltage
- Re-upholster couch cushions
- Replace front mattress
- Install flat panel TV
- Replace flooded lead acid house batteries with 400ah LiFePo battery
- Install folding exterior handle at entry
- Refinish all interior cabinets in new paint scheme
- Remove a majority of cloth accent pieces throughout the interior
- Replace door handles and hinges with new color
- Replace accidentally broken refrigerator handles with matching interior color
- Add freezer/fridge temp sensors
- Add interior/exterior temp sensors
- Replace CH751 locks with tubular locks
- Add sound deadening to generator bay door
- Replace furnace blower motor
- Add Z-Wave electronic thermostat
- Install soft start on AC unit
- Replace refrigerator roof vent
- Install bug screens on refrigerator and furnace intake
- Install remote monitoring and generator starting capabilities
- Add stand alone 20amp 120VAC outlet in generator bay
- Replace 7 pin pigtail and wire box
All of this said, fixing the inherited issues was about $1100 total with us doing the labor, not bad for all new tires, brakes, and propane tanks. The rest of the upgrades would have been made on nearly any rig we were looking at, even new. This is where the benefit to us in buying a used model paid off, it allowed us the budget to customize and fine tune everything we wanted.
We will try to keep a chronological list, and link to our other posts as needed (see above.)
Prior to our first test run, Eric wanted to make sure the tires were replaced, and brakes checked. The first desert trip to Ocotillo Wells wouldn’t be a heavy one, but it is a drive that can strain the tires and brakes. We simply moved the RV to the driveway and set it up on jack stands.
All five trailer tires are off for replacements! These have almost new tread, but are at the end of life expectancy according to the DOT stamps. If this were a lighter trailer, we would have pushed these a season. But we also don’t want to risk a tread separation, and the cost was cheaper than expected.
Our truck was also nearly at the wear bars, and while still safe on road, we would be towing off road in some potentially soft conditions. We didn’t want to take a risk our first time out, and decided to buy another set of BFG A/T KO2s at the same time. Our local tire store was happy we didn’t bring the trailer in tow.
The first drum Eric pulled was in great shape considering. However, as he moved around the axles, this mess was discovered. There isn’t a great way to salvage grease impregnated brake material, and a decision was made to replace all four brake shoe assemblies. We just happen to have one of the few trailer supply houses in San Diego County not far from our home, and they had a set of four in stock, at pricing that was very affordable.
All four brake drums were cleaned, and the wheel bearings repacked. New seals were installed, and the surfaces were clean enough to not need machining.
New backing plate assemblies installed and wired up. These are self adjusting units, which are an upgrade over standard.
Drums re-installed, and ready for wheels to be mounted.
New tires are installed and aired up, and we are ready for our maiden voyage.
The truck is ready with fresh rubber as well.
Our new tanks and connections, the previous ones almost disintegrated when trying to remove the tanks for replacement. And yes, the cover has some rotted wood underneath, it is something we can live with.
Our first trip, and this would be more of a “work the bugs out” rodeo than anything. Yes, this trailer is tongue heavy with all of that propane capacity and lead acid batteries on the front. Eric installed airbags on the truck, and it helped tremendously with the load height. (Airbags do not increase load capacity.)
These airbags replaced the bump stops on our Chevrolet.
It felt appropriate to terminate the Schrader Valve at the trailer plug mount. We tied both airbags together for pressure balancing. We don’t tow enough to warrant an onboard compressor at this time.
Our maiden voyage yielded a good number of wants, and the planning and shopping began. The battery monitor on the hood vent leaves a lot to be desired, as well as the ability to monitor generator/shore AC power. Eric wants to rig up an analog battery state of charge to fit in between these gauges.
The newer of the mattresses was moved to the bunk house, and the older mattress is staged for disposal. This made a huge improvement in comfort for us. Eric is also replacing the universal joints on the truck, they were due again.
The propane leak detector was beyond life expectancy, and we had a hard time finding an exact replacement. A new model was bought, and the dimensions were not accurate on the listing. A kludge using some cardboard gets us back on the road until a proper adapter can be fabricated.
An electronic door lock was installed, and offers key-less access which is great for the beach. We also took the liberty after hosting a few guests to add an oversized handle for access. This trailer sits pretty tall at the stairs when leveled.
A Bluetooth enabled CD player was installed with a dedicated 12 volt on/off switch. This was necessary for our previous electrical situation, and in this capacity it reduces additional lights on at night.
Our first wash of the RV killed the refrigerator vent. A new one was purchased, and needed some modifications for installation.
A taller kitchen sink faucet was installed, and this one incorporates a dedicated filtered drinking water circuit.
Said filter installed below the sink, and tied in on the pressure side of the pump. This allows water to be filtered whether we are on tank or city water supply.
We bought an Acurite fridge/freezer temperature monitor, so we can keep tabs on the system while switching from AC power and propane. This allows us to make corrections when something goes wrong, which can happen when you run low on one tank of propane. Eric has had to switch the valves over at 4am before when the fridge attempted to keep lighting the pilot light off grid…
The interior 12v DC cigarette outlets have USB adapters for multiple device charging options.
We replaced all of our CH751 locks (the MOST common key signature) with custom coded tubular locks. Locks keep honest people honest, as we know. This upgrade also helped as the old locks had wear internally, and were tough to operate.
Our privacy curtain suffered some Phillip attention, and a few of the guides broke. Irvine Shade & Door sent us replacements, free of charge no questions asked. Talk about service!
We opted to have our paint contractor help us refinish the oak and brass motif. He did a fabulous job, and spent a tremendous amount of time masking to spray. The before.
Accent fabric pieces removed. We needed to make some fillers for some of the cabinets, and Eric had some wood on hand that would be perfect after it was ripped to spec.
There was just enough 1″x4″ material length on hand to prevent a trip to the lumber yard.
New fillers in and ready for paint!
The after! This is a color we have recommended to multiple clients for painting their kitchens prior to sale.
All of the door faces.
The drawers after paint, awaiting installation.
New hinges and pulls installed during the reassembly process, and this gives us a much more modern look and feel.
We left a campground and found out we hadn’t completely latched the fridge door, and the weight of contents caused the door to slam open, breaking one handle.
As it turned out, this set of black handles that matched our new color scheme were the only set available that was palatable. It turned out to be a win/win despite the mistake we made.
They also came with these latch cards that hold the doors open enough to air out and prevent mildew, and we have been using them consistently.
After a few winter stays, our furnace fan developed a squeak intermittently, and it was loud enough to prevent us from sleeping. A replacement was ordered and installed prior to the next trip.
We replaced the shower wand with a modern unit, and added a liquid soap dispenser to allow for our different products with little fuss. A 3M self adhesive soap bar holder was installed as well, to add to the creature comfort.
We added a smart TV on an articulating mount, that allows it to be stowed out of the way. This is really the only size and location that would work for us. We access all content over WiFi.
Eric would really like an Ambient Weather station, but this indoor/outdoor combo will do. It has an outdoor sensor that we deploy when parked.
Our mechanical thermostat was inaccurate and wasting propane during heat cycles. We really wanted an electronic thermostat, and RV specific models left a lot to be desired. This Honeywell model can run on AAA batteries, and gives us the best of both worlds. This unit was the only one we could land our hands on, and it is branded unfortunately.
We repurposed this spice rack for additional storage in the bath area. It fits right in with the black chicken wire.
We added some sound deadening to the generator door and vent. Our model is water cooled, and has a very efficient cooling system. We can always remove material on the vent side if it becomes an issue. This made a decent reduction in exterior noise levels.
Our first replacement toilet was a 320 Dometic. It started leaking in between the bowl and pedestal, and a warranty repair was months out. It left a major mess on our last trip, with black water all over the floor. It was disgusting, and customer service could not have cared less…
We switched to Thetford, and have been happy since. All parts are serviceable in this model. A plain white model was double the price of the bone, and it works out that the bone matched our faded shower stall 😛
We took the opportunity after painting to shampoo all carpeted and upholstered surfaces with a Rug Doctor.
We also had our couch cushions redone, with new foam and vinyl. The foam is aviation grade manufactured by Scandia, DAX 55. It is extremely comfortable, and expensive… But well worth the investment for our primary seating area. We chose darker colors that would hide dirt and dust, and so far so good!
A dedicated 20amp outlet was installed to take advantage of the unused stator output. This could come in handy if a neighbor needed power, or a high amerage 120VAC tool needed to be utilized without affecting normal trailer operation.
The Victron Gerbo GX appliance has some robust monitoring capabilities, as seen via screen shot on mobile. This was after a seven hour drive, running the fridge on electric. We hooked up to shore power to run the AC (which we have capacity to do on battery alone) and charge the battery.
That looks like the majority of the projects have been detailed, any more will be added on below!
June 2023: replaced 7 pin pigtail and wire box
Our pigtail worked great the previous tow, but our most recent trip the trailer brakes weren’t working so well. Lots of corrosion in the pins.
A look in the box wasn’t much better, lots of corrosion and poor connections. We found a replacement on Amazon, and simply rewired everything.
Our new box is installed! We abandoned the original vehicle to coach battery connections, the positive taped off here. All new connections and pigtail. Our newer fused battery connections are seen at the top of this image.
All buttoned up, with a more water resistant box. This was well worth the $40 to get back on the road.