How to: DIY Wedge Camper

Thinking about starting this over the summer. I wanted to ask couple Qs to those of you that have done this build. First is how are the 3mm panels holding up. Are they strong enough for the floors and ceiling? Second is has anyone added a rack to the top of this? I was thinking crossbars attached to the top extrusions to hold paddle boards, etc. I worry that the top extrusion frame being smaller pieces won't take the weight. Anyone have any thoughts on those two things? Thanks for putting this together! I'll be buying the cut files soon.

 

As long as you have the spaceframe as support, the 3mm floor works great. But as discussed on nearly every page so far, an RTT build will need something different.

Can't comment on adding a rack, haven't tried that.

 

Such an amazing build! This looks AWESOME! Might have to build this or something similar when I have time in the future. Thanks for providing all this info!!

 

What thickness are those panels? And are you planning on welding the top panels together? Looks really good!

 

The roof, sides are .060" and plenty stiff. The doors are eighth inch thick. Really heavy..lol. I have no idea what ga .060 is. ....16 gauge. Just looked it up..ahahahaha. Thanks for the kind words.

Edit. No on the weld. I'm not TIG AC/DC capable. They are butted with factory cut so it's tight as crabs ass...lol

Zim

 

Hey @Ripcord, did you use the extrusion weather seal between the "floor" panel and extrusion (not the panel/frame interface where the cork rubber is used)? No pics in the build but it seems like you'd mount the floor to the 4.5 extrusion the same way the roof mounts to the upper 1.5" sections.

Should have my frame drilled and painted today - the fellow who welded it for me created a 3" overhang in the front the first time, but is a solid dude and fixed his mistake por gratis. Been dragging along, time for some progress.

 

The mounting of the roof & floor panels to the extrusion both used that small wiper type seal that fits in the extrusion between each slot nut as this image shows:

 

I had to outsource to a shop for fabrication of frame. They flipped the 1” square tubing supports upside down! There’s little structural support to them, but whatever...the price got knocked down. Tapped all aluminum extrusions and test fit them to get holes on frame in the right spots to prep for paint.

I opted for 10’ long wedge. The deflection is minimal with simulated weight of legs on it in laying down position. Long bed plus double cab paid off for once...lol

 

I’m guessing my mistake was doubling them up as I was already out of the quantity in the build list! I thought I wouldn’t get a good enough seal with one piece as shown, but clearly you did, whoops. Ordered a few more from McMaster.

Once the seals are in I’m putting this damn thing together. Primed and painted the frame after drilling. Currently riveting the aluminum angle to the doors, riveted the hinges on the frame this morning. Raining tomorrow so I’ll finish sewing the tent, yeewwwww.

 

Looks good! I’m in the process of building mine now too. I see that you used a 3” bottom extrusion on your wedge. Any reason why not the 4.5”?

Also, what’s your height from the roof to the bottom on the camper?

 

honestly, since I won’t be using a bulky mattress (and you really only need a 4.5” extrusion for the storage space, not necessarily structural integrity), I opted for the 3”. As of right now, the extrusions hover over the highest part of the cab ~1”+ under load, and slightly more when not. I don’t want a roof rack under it and can always make a spacer for the frame-to-wedge interface if I do want more room.

 

Gotcha, yeah leaving mattress and sleeping bags is a must for me. I opted for the 4.5 on mine. But I do like the slim look on yours.

did you use Ripcords CAD files for the side doors on your space frame?

 

No, I didn’t. I got a file for a Tacoma long bed off turbosquid and created my own CAD design, much like Ripcord’s.

 

Cool, I’ll have to check that out.

 

Anyone interested in buying a camper, my V1 camper is back up for sale. He never even used it and is selling for what I sold it to him for, $4,500.

https://www.instagram.com/p/CA6ZFHiHYEH/

 

Just went on a ordering spree, I was able to find the gas struts right at $20 cheaper on Amazon. Excited to get started! Are all all the southco latches on amazon and ebay knock offs? PCM surplus is out of stock.

 

from what I have seen, yes. genuine southco seems to be hard to come by. Which sucks because the knock offs have huge gaps around the mechanism that let dust in.

 

Drilled 90% of the holes, primed and painted the space frame. Just a quick mock up of the layout. The sleeping area is 7’ long on the dot, with 3’ of open space over the rear of the bed. Stoked to keep pushing forward with this one.

 

I bought each set from different dealers out of necessity and they’re good to go, seems ymmv though.

 

Finish the tent this weekend and I’m DONE. OK fine, still have to put the rear hatch on but at this point in the project, that seems as difficult as, well not that difficult at all.