North American Sojourner Build and Photography

After posting over in the "what did you screw up on your 3rd Gen today" several times, I thought I'd better do a build thread. Most of the folks over there are the buy and install type which is fine, but I'm making 80% of my gear, and that's a whole different story. Plus, I don't have the wallet they do. Lol​

So a little about myself;
Outdoorsman all my life, Scouts to Eagle, thousands of miles backpacking, climber, National Ski Patrol, European Division and Mountaineer.
Now I'm too old to do the above but the adventure still is there. So I bought a truck.
I've been looking at the Tacoma for a while. Worked on a few as a service tech, and the customers were really happy with them.

Picked up the 2019 AC SR5 in January 15th this year. Still only has less than 3,000 as of today.
I did some basic things like phone mounts, IPAD mounts, and then started on a camper shell. I'm about 80% done with that as of today and I'll update as I go along.

I started with a 1x1 frame sitting on 1x2 base. I'm using @Ripcord's build as a inspiration, if I needed one...lol. He did a outstanding job.



Instead of using composite sign material, I'm using aluminum, .060 for the shell, and 1/8" for the doors. There will be 4 doors, 2 on each side, and the door in the back. I'm not doing any kind of tent at this time, but I have several cutting tools should I decide to alter it...Lol



So I don't have any cutting ability for long cuts. I have some shears (milwalkee) that do well on sheet metal, but cutting a straight line is a challenge. I have to do lots of grinding, sanding, filing and cussing. It's a lot of work.


I love these latches....they are knockoff's of what @Ripcord used but they are nice.

 

So as this thing was developing, I've also created some other little enhancements to make life easier on the road, or off the road as it may be. First was the phone and IPAD mount, both from Ram.



This mount is for the IPAD air, and I have another for the 7th gen. I have Gaia maps loaded, and have the Dual GPS unit as my SAT finder and plotter.



This system is awesome as even without phone service, you have GPS capability.



I also will have some radio's so I started with the CB, and decided to put it in the back. I don't need all that stuff up front so I fabricated a "command center" lol.



So the above was a mock up, and I've changed a few things, but I love the setup. It allows me to get the junk from the front to the back, and the mike still reaches. Will also have charging stations, voltage monitors, and a fuse setup for the cabin electrical.
Also did some seat covers...I'm a practical, utilitarian kind of guy, no bling, bling, just stuff that works.

 

I fabricated the antenna mount and went for the fender mount. Looks good, keeps the thing low. We will see how it works out.





Got to have the flag, after all, this is America!

 

Finished the 3rd door today. Each door is about 3 hours of labor. Aluminum sucks...lol
Zim

 

This is the winged camper..lol. Looks like it's going to take off.
All doors have shocks, one each for now. I'll add another shock to each door later if I decide to keep this design, or sell the whole thing and build another..
Zim



This butt joint in the roof is a pain. Close tolerances so I'll have to use a smaller rivet, and stagger them. I think it will be strong and dry.

 

So this was fun. I found these porch lights and decided I needed something to turn on if I get to camp late. This will light up each side of the camper area so we can unload our gear.
Zim

 

On the truck today for the hold down brackets. Off again tomorrow or Thursday for paint.
Zim

 

So paint was fun...not. I'm not sure it will hold up, but having a professional paint it is not out of the question. Gasket is .75" cork.
Zim



Frame paint is "Hammered" rattle can.


I also added some lights while it was on the ground. Easy on the back that way.

 

Getting ready to build some aluminum panels for the driver side forward door. I'm going to have a electrical panel there with light switches and charging stations, etc. I had to make a sheetmetal brake first.

 

I think I forgot to add the finished picture of the ICC or "International Command Center" LMAO...It's done for now.

 

Well almost finished. Paint done....have some small things to clean up, and make the rear door. It's been a ass dragger..Lol
Zim

 

Did a little sheet metal work to make a electrical panel in the first door, passenger side. Used the home made brake.
Zim

 

No lie. I had this first aid kit out of the truck 5 times in 2 days on the first camp out...lmao. I built all this crap, and bleed more using it than building it. LOL.



There will eventually be some charging stations here, and some other electronic crap as I get it.
Zim

 

First camp with this setup went great. Will make some changes, and head out maybe when it cools off.
Zim


This guy wanted something to eat.....he had some balls getting this close. Lol


The lights are awesome. Had almost too much light.

 

Here is the kitchen I made. It can go on either side, I have 2 bolts coming up to mount to. Legs are adjustable, and it all folds up and into the truck.
Zim

 

Looks great! What is needing improvement/fixed? Seems no animals have any courage like that when I go camping. My 2 furry travel companions are likely the cause.

 

I'd like to narrow down the kitchen gear. Had too much I think, but did use almost all of it. That big aluminum box is great, and everything fits, but it's too big for one person to drag around. I'd like to get the cases with wheels for this reason. Tarps need to be figured out but that would depend on the camp site. Other than that, I'm really happy with everything.
Zim

 

great work on the cap. It's solid and should hold whatever weight you want to put on top as well. The kitchen setup is pretty slick as well. I love all the DIY fab work it's worth far more to me than just buying stuff, not that I haven't. With our micro camper we bought the basic camper but i had to build alot from there to get what we needed and that's the point when you build it you usually get what you need.

 

Gotcha, I've been shrinking down my kitchen supplies for a while. Realized I dont really need much since I'm only cooking for myself most of the time and I'm not much of a cook. Think I'm going to start preplanning more and pre cook a lot of it so I'm really just needing to heat it up and enjoy a good home cooked meal.

Builds like this and your camper have inspired me a ton. I dont have a lot(virtually none really) skills at building things with wood or metal. Havent done much with wood in 20+ years and never worked with metal until a few months ago when I started learning to weld. I have big hopes for what I will build in the future thanks to all the inspiration I get from everyone on this site and the great people who have helped me and continue to do so.

 

I will humbly offer you the best piece of advice i recieved when I started welding/ fabricating. "Don't be scared to try it! The worst that can happen is you cut it apart and do it again."