How to: DIY Wedge Camper

Thanks for clarifying that Jim!
I will have to measure that and see how it will fit on the Hilux.
Do you know the reason for why its done like this? I reckon GFC has done the same, but for what purpose I wonder?

Thanks again!

 

I think it is to follow the line of the cab better. You could copy the same slope from the front to the back if you wanted to keep it looking symmetrical but it likely doesn't matter much. Mine is (in drawing form) the same offset (2") to keep my material sizes the same for easy of fabrication.

 

You may be right there, the more i look at it the more i like the slope design. Almost all canopy mounts for the Hilux is pretty much dead square which is quite boring and the reason i have not bought one yet.
Jim's and GFC's design really sticks out! Me likey!

 

where did you get the maxtrax and hilux models?! they look awesome!

 

Found it in the sketchup 3D warehouse
https://3dwarehouse.sketchup.com/model/65b13ab8-7a6a-45e5-b14c-1872d6ae8ccf/MAXTRAX

 

thanks! I've always used grabcad! Now i have another resource!

I gotta see if I can use this file type in Solidworks 2019 though

 

@Blais03

 

It’s cool but I wouldn’t spend 2 grand on it

 

Nice build man!!

I also went with square tubing all around and plywood sides. A bit on the heavy side but works well! Also don’t have the knowledge or experience as you do.

 

Nice! that turned out way cool.

 

@Ripcord have you seen or checked for any measurable deflection in the cantilever over the cab, I'm trying to plan out something similar and an looking between using the same 1530LS profile you have or possibly going to a 1030S
I've been using the 8020.net deflection calculator, but don't have a realistic weight to put in to figure it out

 

The deflection I see is from hard hits during wheeling, not from having people in the camper while parked.

As such, the V2 camper will have 4.5x1.5" extrusions on bottom and 1.5x1.5" extrusions on top, so still 6" overall but the bottom (which is really the only structural part) will be much stronger. Still need to update the spreadsheet to reflect this.

 

Good to know sounds like I won’t be using 1030
Is your 1530 the lightweight version?
Also makes me wonder about deflection on the GFC in similar situations

 

4.5” and 1.5” is the top I used. I haven’t seen it deflect at all. We also sleep with out feet towards the cab over sections.

 

I have the 15 series Ultra Light Weight. Before I bought the 80/20. I had a buddy who had a 4’ piece. I placed it on my frame and put my entire weight on a 1.5x1.5 piece and I believe it moved about 1/4 of an inch down the middle. I weight 200lbs

With multiple pieces to hold up weight (cross bars). You should have no issues.

 

yes the lightweight version. I am pretty confident in the 4.5" tall spec being rigid even during hard wheeling.

But what about when wheeling? As I said above even the 3" tall 8020 has no deflection when people are just sleeping inside, thats not the high load scenario that rock crawling is.

 

This build is killer!! trying to decide if I have the cajoneys to try it myself. I love the idea of an all in one solution.

 

@Ripcord Love your build and very impressed with the attention to detail and thoroughness of your threads. Big props. I'm currently designing my own wedge. Have you had any issues with water infiltration? Specifically around the front of the tent where the canvas meets the hinge? How did you seal this area and the rest of the tent attachment points? I noticed you used a flap to drain water over the extrusions.

 

The felt has been the only main area of water intrusion, through wicking. Using the cork/rubber gasket I mentioned in the spreadsheet will resolve that.
The 3 piece roof had some intrusion at the connections between panels but doing a one piece roof will solve that.

The skirt on the tent does a great job, there isn't a need for any tent fabric on the front (at the hinge gap) for rain purposes. Trust me its been slept in during some decent storms. It does create an air ventilation gap though, and for that reason my V2 camper will have material there.

 

@MattJakobs here is another one that is also build extremely well and I see @CalTacoma09 is doing his homework on here too