How to: DIY Wedge Camper

That's the 600 Denier Polyester that Ripcord Lists in his Spreadsheet, in the 'Smoke Grey' Color.

 

What were the dimension of the windows you went with? I was fooling around with some measuring and cost, looked like you did roughly 30x12" ?

 

I Bought 2: 24" x 48" pieces of 3/16" Tinted Lexan and cut them to fit with a jig saw.

The Generic Name is Polycarbonate Sheet. It's not Acrylic Sheet. aka PlexiGlas.
Lexan (Polycarbonate) is basically shatter-proof.

 

Shit, that's bigger than I thought. Thanks!

 

The installed lengths of the windows are approx. 15" x 45 1/2", I just measured real quick. I ordered the 24x48's because they were a stock size that the supplier carried and weren't subject to a 'custom order'. which involved some other sort of shenanigans or something. Just going on memory here, there must have been a good reason why I did it the way I did it. The thickness was important (3/16") because it was right in the middle of what the tolerance for the glass seal was.

Cheers.

 

Pro tip for those wanting to cut polycarbonate. It does not laser cut well. It’s meant to be machined on cnc.

 

Did you get it through a local supplier or order online? I'm seeing crazy price variance from different places local/online. Anywhere from $60-$180/sheet for a 24x48" of the dark grey tinted. Local shop has 12x48" tinted for $60/sheet.

Definitely sticking with the 3/16" thickness. Already ordered the glass seal you originally linked.

 

I originally built the camper using 9/16” tall hatch dust seals and I’m experiencing water seepage during rain. Has anyone stepped up to 3/4” or even 1” thickness seals?

Thanks

 

I bought it from a supplier called 'piedmont plastics' you can look them up online. They have a distribution point near me, so i went to the warehouse and picked it up, but they ship as well. I think I paid about $88 bucks for both pieces. The price from the dude I called on the phone was better than the price listed on their website. Worth giving one of their people a call I suppose.

 

Do you mean the bulb seals on all the doors?

 

Hey for those of you who have mounted @plurpimpin @Jarman02, did you guys drink the double bulb seal to the bed rail or directly to the space frame?

 

Yes.

 

I did mine to space frame

 

I got the 13/16th’s per @plurpimpin’s recommendation. I think they’ll be great for around the door but I used a different hinge so they’re a little too big for the top so trying to figure out a solution for that part

 

I did the butyl tape on my bedrails and then stuck the bulb seal to that. I don’t think it matters much one way or the other.

 

Might be best to do the bulb seals on the camper it self. Would make removal and reinstall somewhat easier if one had the means to do so.

 

Shit, there is one of the warehouses 15 minutes from me. I actually looked at their website a few days back, saw $120/sheet. Didn't think about calling

 

I stepped up to larger bulb seals for the doors and still get water slightly seeping in around the hinges. I found the issue is the back of the seal and water seeping behind the seal where the hinge is due to the adhesive not sealing around the hinge. Gonna have to think up something to solve that. I think putting the bulb seal below the hinge flange would then not allow it to contact the frame properly to seal.

I did make my own stiffeners to go around my latches. Massive improvement.

 

10/10 would recommend not using cheap aftermarket gas struts lol

 

Forgot who wanted photos but here’s how I dealt with the corners.
You can see it on the bottom of the photo where I cut the top portion of the mount so the awning track sits flush and goes all the way to the corner.

on the top is some brackets I designed and 3d printed because I wanted to try it out instead of cutting the aluminum mount. Very little stress so 100% infill petg plastic should be plenty strong.