How to: DIY Wedge Camper

Do you happen to know the part number for this?

 

Yeah, a little pricey for what they are.
https://www.mcmaster.com/2206A34

I got stainless, but they have a zinc option for a few bucks cheaper:
https://www.mcmaster.com/2206A21

The springs seem nice and stiff, so I’m not worried about them disengaging when hitting bumps, especially with the pressure from the latches grabbing them. Though if I were to do it again, I’d flip them the other way around so the handle was at the top. I thought the latch would be too low on the panel, but not really the case.

 

I had a similar alignment issue during my final fitment a few days before a trip to Moab. To say I was stressed and pissed at myself would be an understatement.

I took care of it by loosening every bolt, clamping the extrusions together so that they're flush, and then tightening everything down.

I suspect that the corner brackets from T-Nutz aren't 100% square, so over-tightening one of them could make one corner acute or obtuse. So tighten everything down evenly, working your way around, and you should be able to reduce that error.

I also widened the tolerances for the holes in the composite panels and the space frame to allow for easier alignment and squaring.

 

I checked corner to corner and the main frame is only like 1/16 or so out of square and that’s an acceptable amount id say

 

I am never ordering anything from Tnutz again. Not only are their parts inferior to 80/20 they have pretty bad customer service. Its not worth the savings to me.

 

The corner brackets are not square by design, quoted from 8020s website "corner bracket engages the 2-degree drop-lock feature when the assembly bolts are tightened to the required torque."

 

Well guess I’m going to dump the Tnutz corner braces and brackets then. They are all absolutely trash

 

When installing the gas struts make sure your angled aluminum covers enough length.
Like in the pictures below you can see that my panel is already denting out.

i now consider to maybe install 20lbs ones instead

 

How far are you guys putting the struts?

 

Is that from the corner of the aluminum pushing out? Or from the head of the strut contacting the panel?

 

You can also grind a lot of the plastic head off of the gas struts. That's what I did with mine to get them to clear. There is a lot of extra plastic on there

 

What’s your alternative? They are cut from the same stock that 8020 uses.

When bolting these assemblies together you have to make sure everything is square yourself. The holes are not the exact size of the fasterners.

 

It is from the corner of the aluminum. the gas strut heads are not touching.

 

Are there two separate pieces of angle aluminum meeting at the corner?

if so that might be part of the problem

 

Yes it’s two pieces coming together..should be visible on one of the pictures I uploaded.
I saw this early in the build and was hoping the diagonal piece is helping to support it.

 

I did square everything up, im only a hair under 1/8" out of square but my roof panel is the culprit.

Also TNutz's corner brackets are poorly machined and the finish is subpar when compared to 8020. Mine look like they are factory thirds from 8020.

 

Got the frame mounted to the wedge today. Are u guys setting any type of torque for the bolts? I did mine a little differently than Ripcord’s though

 

If you used the chintzy slot nuts from tnutz they strip easily. I used the beefy style from t nuts and will go back and blue loctite everything with the torque spec of “gutentight”.

 

Doors going on without stiffeners just so I can get it out and on my truck this weekend. I purchases the hinges @Taco Camper used on his composite build. Much better than Home Depot hinges. You just have to drill out the holes yourself. I should not have put the holes in the center of the hinge mount just so the ACM panel has more meat on it from the edge of the hole.

but I should be ok. Totally want to wrap the panels already since the ACM scratches easily.


I also need to slot the holes so I can adjust the door up and down because my rear latch isn’t closing all of the way.

 

definitey remember to wrap/coat before the stiffeners... i forgot lol