1 Bored Clerk's Garage Built Camper

Borrowed a laminate trimmer (very small router) from a friend at work. I’m hoping this will work nicely to help me create sturdy mounting points for the boxes on the camper. Hoping to get into that toward the end of this week and over the weekend.

 

So will you have extra time with the holidays or will you be tied up like the rest of us?

 

I have whatever time I want.

It does look like I’m getting the new springs for my dirtbike Friday so if I’m going riding on Saturday, I’m going to need to spend Friday night installing springs.

 

I’m currently waiting on the parts for the modification myself.
Glad to see this solved the issue, it will be nice to not have to babysit the gas nozzle when filling up the truck.

 

For real. It was maddening!

 

Test fit one of the boxes tonight! It fits pretty well. I’ll need to make some spacers of various thicknesses to fully support the box properly against the camper walls. But overall, I’m pumped about it!


I made this disc as a way to drill a center hole with enough clearance around it for the router body to clear the camper walls. Below are a couple of examples of that in use. I’ll be routing out some 4” diameter holes in the wall of the camper that are 1/2” deep. Then I’ll epoxy some marine plywood in there and mount a stainless furniture nut then epoxy over the whole thing. This will give me a blind fastener to attach the box with. No exposed hardware inside the camper.

 

Love the box! I had only pictures in my head of what it might look like but man that is much better than I imagined.

I like the idea of not being able to see the hardware indies also. Will keep it very clean looking

 

Ok, so I just spent the last hour reading this thread in it’s entirety from day one. I was subbed back when it was just a bed insert build and somehow lost track.

Holy Shit!

Talk about dedication and determination!

Bravo sir!

Personally I was fortunate enough to find and purchase of Flippac back in September. I then sold my leer cap and am in the process of selling my CVT RTT.

This is some next-level shit you’ve got going on here!

Kudos for the custom fabrication, I gave up of fiberglass nearly 8 years ago with the grill work I do in favor of plastic welding. The patience and skill you’ve developed are admirable to say the least.

Totally hooked for updates now.

 

Once the camper body is painted, the two aluminum boxes are going to pop! It should look awesome! Plus the aluminum L track and all the other expo jewelry! Haha.

 

Thanks! And welcome back! The process is slow but I’m fairly confident I’ll be able to finally get this thing on the truck this winter...sometime.

 

Merry Christmas! Maybe Santa will send some elves to help with the build! lol

 

Merry Christmas! I was holding out for the elf delivery...hasn’t happened yet. So I’m just going to get back to work on the camper myself.

 

Christmas labor!



I drilled the pilot holes for the rear corner box. Then I routed out a recess for each hole. I’ll epoxy in a plywood disc at each location then carry on with mounting hardware and whatnot. Feels good to have just made a decision and moved forward on it even if it’s wrong.

 

Disc mode: ENGAGE!


Cut out all of the backing discs for the aluminum box mounts. Epoxied two of them in place before I ran out of six10 epoxy. I prefer the thickened epoxy in a caulk style tube because you can more easily fill all of the exposed core material for good strength and bond. It has a mixing tip that fits right into each honeycomb void. It’s time consuming but it’s the right way to do it. I can mix my own thickened epoxy but smearing it on from the top of the honeycomb void just traps a big air bubble in the void and you get crappy bond and strength properties. The only issue is that the six10 epoxy in the tubes is crazy expensive...and I need a surprising amount of it to finish the box mounts.



I also reinforced the edges above and below the door. I hadn’t done these yet so now they’re done.

Feels good to keep cruising along and crossing things off the list. I hope my plan for fitting the boxes works out in real life as well as it is in my head.

 

Just put a metric crap ton of six 10 epoxy on hold at my local store. Positive attitude says: now I can finish these box mounts at whatever pace I want! Negative Nancy says: that’s $320.

If there was a better way to get this done, I’d do it but this epoxy and, more importantly, the delivery system is ideal for this process. So, I’m paying a hefty price for efficiency and confidence that it’s done as well as I know how to do it. I guess that’s a win?

 

Win/win

 

I've used Six10 before. I really like it, too.

As you said, the delivery system is great.

You have so much time into this project, may as well it do it right. It will pay off in the long run.

 

The blue tape stars of progress!! I finished setting all of the backing discs for the rear box mounting hardware.


Here’s two that are mostly cured. I’ll sand these smooth when the others are ready and then carry on with getting that box in place!

 

Do you already have the windows for it?
Maybe I missed that...

 

I do. I gave them the measurements I wanted and had them built. Then I’ll cut the window holes to match. I already cut the back window. There’s also a small front window to match up with the cab window and a small window for the door. Single pane as I hear dual pain is a no-no for off road.