How to: DIY Wedge Camper

Has anyone used these canopy clamps instead of welding mounts? Utilizing the existing rails of the tacoma?

$49 API Clamps (6 Pack) Silver Compatible with Toyota Tacoma - 2005 & Newer - Mounting Channel Track Truck Topper Cap, Camper Shell

https://www.amazon.com/API-Clamps-S...ds=tacoma+canopy+clamps&qid=1616775265&sr=8-5

 

Making progress. For the 3” upper extrusion looks to me the side locks aren’t needed as much.

How are people sealing this section at the edges? Just with cork?

 

The frame is done thanks to my friend Russ who TIG welded the whole thing. If anyone in the PDX area needs welding help he's your guy. Planned on doing small gussets but ran out of time... Russ welded nuclear submarines so I'm confident these welds are holding up with or without...

Mocked up the doors and they fit great too, so I'm ready to drill holes, clean it up and paint!

Then a temporary roof out of some cheap painted ply while I wait for the GFC superlite to mount on the top. Going to cut the floor of the super light and seal it up to this frame to achieve the same integrated camper design. Pretty stoked!

 

I've got one available in El Segundo. You can have it for free. May have to modify for your application. Had a rough go at it, but it will work, as long as your level and have shims.

 

Has anyone found a supplier for the external gussets for the 4.5 tall extrusion? I'm doing 4.5 on bottom and 3in for the top frame. Trying to get the hardware and extrusion this week.

 

The 4.5” 3 hole tall external gussets do not exist. You have to make your own from the raw stock 8020 sells


Took 8020 about a two weeks before my order shipped. By the way

 

Ok, I know it was mentioned using different sizes, as I don't have a way to mill these. I have my cart ready at 8020 and am now discouraged haha

 

How are your clamps holding up? Any issues?

 

You’ll have to stack 2 or single hole gussets. That’s what I’m doing until I get better at accurately milling holes. A friend of mine with a machine shop was going to charge me $60 to make the tall gussets

 

I'm scheming on the tent portion right now. Looking at the V2 GFC, it looks like their main windows and rear doors are covered with what is essentially a big flap - attached at the top, zippers straight down the sides, not attached at the bottom. Then inside the window is a bug netting, with a zipper all the way around. It looks like they are using a #10 Vislon zipper as some in this thread have done as well.

Has anyone tried something similar? I definitely like the idea of having the bug netting inside the tent portion so it doesn't get wet, and this does seem to simplify the zipper part a bit because only the bug net zipper needs to have curves and the bug net zipper doesn't need to be waterproof. It also seems to depend less on the waterproofness of the zipper. I guess it does require more tent fabric because the flaps are actually larger than the "holes" they cover, but I do like the looks of this.

 

Anybody have any solutions or ideas of how to work the keder rail properly around the 4 hole corner brackets? The obvious solution is to cut it but I’m trying to figure a way where I can keep a tighter fit in the corners for but mitigation. Next obvious option is to place behind but that has me worried about proper figment of the corner brackets.

 

With 8 of them, it is solid as a rock! Re-torqued them a few weeks ago and haven't touched them since.

 

Anyone know where to get the tent window tensioners and brackets for the rear window?

 

Finishing my build up this week and thought I'd share a few things:

Install by sliding bottom extrusion on to preset bolts/tslots nuts:

I took a page out of @NotTaco's book and did the install with the frame right side up (vs upside down). Was pretty simple. Slid right on and tightened up.
For sealant, I used painters tape and a caulk tool and ran a thick bead between the frame and the extrusion. The silicone completely fills the cap between the extrusion and frame (covering the cork). I skipped the rubber gaskets in the extrusion as per @Jarman02's suggestion.


Looking to do simple tie down points on the ceiling inside the lower camper portion for a cargo net or other storage?

$11 DEDC 8 Pack Hardtop Quick Removal Fastener Thumb Screws and Nuts, 8pcs Tie Down D-Rings Anchors Replacement for 1995-2017 JK YJ TJ JKU Sports Sahara Freedom Rubicon X & Unlimited (8 Packs Anchor Set)

https://www.amazon.com/gp/product/B079DQ55SH/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8

Best to be installed when you attach the space frame to the extrusion and they basically replace one of the washers you put on each of those bolts. They are small so fit perfectly on the space frame.

I ran 4 on each side and 2 in the middle support to create a bungee paracord storage area (similar to what people do on the GFC's with cargo nets, I'm going to add a third bolt and tie down to support the last section of the paracord zig-zag). They are light duty but great for securing camp chairs, sleeping bags, ski poles, etc.

Also put 2 on each side near the entrance just in case I wanted to add something else down the line (paper towels roll holder, clip random stuff like hats, jackets, etc)


Exhaust Fan?

$93 SOLATEK Solar Ventilation Fan with Battery for Boat, Yacht, Camper, Home, White

https://www.amazon.com/gp/product/B07VQ56QX7/ref=ppx_yo_dt_b_asin_title_o05_s00?ie=UTF8

I went with this Solatek model from Amazon. Someone on the GFC forum has had it for about a year and was happy with it (exchanged some messages, the Marinco model is more expensive, but maybe a buy once cry once scenario?). This one is solar with a built in battery so it can run at night. Has Exhaust/Intake modes on a switch. Doesn't move a ton of air, but easy install and I spaced the install incase I ever wanted to go with a 14x14" Maxxfan.

Run trim around the entire panel?

I ran trim around the entire panel and used a dremel tool to just cut out where the hinges go, while still maintaining the trim on the outer/top portion. Really makes a difference if you are doing contrasting colors (my truck is white with black trim, camper is white with black trim/extrusions/rivets).

Also a good trick for applying the trim is to heat it up with a heat gun/hair dryer, allows you to stretch it around the corners of the panels easier.

 

Howdy, would you mind giving us updates on this mattress? is it too wide for the camper? mine measures to 50" wide, I assume the width of 52" will be too wide?

 

How is everyone mounting awning? I just bought a 270 awning and im struggling on how to mount it. My thought is to attach a 3.5" corner Brackett the 8020 (like the one used on the inside of the tent, but longer). Then attaching the awning to one the some size as the inside corner bracket. Then putting a pin in the top and a bolts in the bottom hole, so thay it can rotate down to access the side latch. How have you guys attached awnings?

 

i really like this concept.
https://ironman4x4america.com/awning-quick-release-mounting-brackets/

i ended up using that as inspiration for my own mounting system since I have a pretty heavy awning. Which 270 awning do you own?

 

I went with the overland vehicle systems 270 LT. I really like that concept. Do you have any pictures if how yours is mounted?

 

Found a killer deal on 8020 in my area, but it's not black anodized. Is this a huge issue with durability? I don't care so much about it being black, because I can paint myself or wrap the outside of need be.

 

personal preference if you want black vs natural aluminum. I went with silver since I have a white truck and will be doing white side panels.


got my composite panels today and cut them out. Went to Polymershapes in Orlando,FL. They have locations all over the country so check them out. the 5x10 ACM was $82 a sheet and the 4x6 was $52.Aside from putting two holes in a side panel that will be covered up by trim I hope all went well. I omitted the stiffener holes and stupidly removed the holes for the 3rd brake light.