Complete Pop up camper/ roll bar build

Below is how I built my pop up camper that also functions as a roll bar. I have been mulling this design over for a few years and I'm stoked to have it to the point where I can share it!

First, I'd like to say a big thank you to @Ripcord for his thread "How to: DIY Wedge Camper Build". He is a skilled engineer and I used a lot of ideas from that thread. I won't repeat anything from his thread, instead, I will focus on what was unique about my build.



My goal at the beginning of this project was to make a camper whose frame also functioned as a roll bar. The frame started with this roll bar portion.



I used angle iron to bolt the frame to the bed. The rest of the frame slowly took shape.


This was the finished frame. You can see the kickers which strengthen the roll bar, and the frames for the side windows. (More on the windows later).



I painted the frame using Raptor Epoxy primer. I don't have a spray gun so I just brushed it on in multiple coats. It has been a few months now and I am very pleased with the durability and finish of the epoxy paint. It is a smooth, semi-gloss coat and lays on nice and thick.



Next, I cut the sheet metal that was going to form the sides and back. I got all the sheet metal and windows from an out-of-business camper shell factory that was liquidating their stock. It was very fortunate timing.



The camper started to take shape! I installed the front facing slider window first, and then put the frame back on the truck and installed the sides and back. I used a combination of 3/16 and 1/8 rivets to fasten the sheet metal and windows.

One thing that I would do differently next time: For the window frames, I would pre-drill the holes on a drill press, then weld them onto the main rack. Drilling the holes with the frame already welded on sucked. I sealed all the seams with RTV.



Side windows installed (They are able to fold out and have bug screen behind the glass)



Back hatch (Ignore the rest of the stuff on top for now!)



Here is a closeup where you can see the trim that I used. The trim is held on with a few sheet metal screws. Next time, I would install the trim and the sheet metal together using rivets.



Installing the bottom of the tent frame. This is where I used Ripcord's ideas with the 80-20, Alupanel, etc etc. You can see the hole towards the rear where a hatch will be (Similar to GFC's transforma-floor). I made the tent section 8ft long so that I could buy materials in standard lengths. Make sure you put T nuts into the T slot for accessories and the Keder rail before you bolt everything together!

To install the T slot, I first drilled the holes in the frame and the Alupanel. I then threaded all the bolts to a T nut and installed them into the holes through the frame. I then had someone slide the T slot on slowly while I lined up the T nuts so that they slid right into place.



A view from the inside:



Here is the hatch that I built. More pics of how it works below.



Here you can see the brackets for the roof rails and the latches that I used.



Frame complete:
I used 120lb struts to help with the weight of the Thule box. The roof rails were made with angle brackets and 1x1 T slot tubing.



Of course I had to take it camping right away to test it out.



Next began the sewing. I did this very similar to the way Ripcord did it, so I won't say any more other than that using a chalk line really helps with making all the long, straight cuts that are necessary! I used a 1000D Cordura nylon fabric for extra wind resistance.



I used a regular sewing machine. The sewing took me about 4 days



Camper complete! Time for the maiden voyage





Looking up (you can see the hatch is slid back underneath the mattress)



Looking down (with hatch open). The hatch rests on the angle iron tabs that you can see.



Confirmed that the setup is waterproof at turkey camp this week:



I am super happy with how it turned out and hope that anyone else looking to build one can get some ideas from this thread. I am very glad that I put in all the windows-- having all the visibility is so crucial on the highway and out in the woods.

Thanks for reading, and please feel free to ask any questions!

 

Reserved for future updates

 

Very cool to see one of these on a 1st gen Single Cab! I've been looking into doing one of these for mine, and you're giving me ideas.

How long is your tent? It seems like most people building these are doing something like 96 inches, which seems like it might be a bit long over a single cab.

 

Looks good! How's the wind noise with the slotted 80/20 (I always wondered if it whistles at highway speeds; the bars on one of my old roof racks used to do that so I put tape on them to help)? IIRC, they make rubber strips for the 80/20 that fit in the slots.

Side note, with it sitting on the bed rails I wouldn't call it a roll bar, just a bed rack (roll bars tie into the frame and provide roll over protection. When my '95 Tacoma got hit and totaled it racked the frame and the bed and cab where visibly warped and misaligned; luckily it wasn't a roll over but it was a hit to the driver's side front corner. I'd probably still be driving that truck if it hadn't been hit, somehow it had more personality than my '05 and reliably took me all over the bottom half of the country.

 

Thanks! The tent is exactly 96". That way, I was able to use standard 4 and 8ft lengths of 80-20 and a 4x8 sheet of aluminum composite.

 

The wind noise is definitely noticeable. I am going to either order or make a wind deflector here soon. I have been looking at the Inno racks one.

Re roll bar: Most aftermarket "Roll bars"/headache racks are designed like this. By tying it in all the way down the bed and adding gussets, the load is spread out pretty evenly across the bed.

My dad walked away from a 30mph roll over with a roll bar exactly like this one.

Obviously it's not going to protect against a high speed rollover, but it will help significantly with a low speed one.

 

Nice work and awesome rig.

 

Thank you!

 

re. wind deflectors, check your local phone book and see if you have a plastics dealer. They should have something that'll work and possibly cutoffs which would be cheaper than buying ready-made or a whole sheet; you've obviously got the skills to shape it and make the brackets.

 

Currently researching how to create my own camper similar to this. I’ll be taking some notes from this build.

Great job!

 

do you wanna sell the camper?