How to: DIY Wedge Camper

Ah my bad. I didn’t notice the username. I’m still confused about @nanserb cause he said he wanted a fabric that was gridded rip stop. But the fabric he linked isn’t that. And the only fabric I could find that met his description was the one I linked.

 

Yea my cap was kinda beat up too, mostly the roof which is gone now, but I just realized how many dents were in the doors and sides. Never realized how thin the skin was on these contractor caps. If I can’t hammer out the dents then I’m doing the same and ditching all the original metal. I am also trying to figure out a solution to the front bulkhead. When I cut it out I’ll need some kind of cross brass to put in there and support the overhang from the tent. I’m also thinking of adding some angled supports to the opening where the doors are, without the roof they seem very flimsy.

 

Whoops, you're correct the one I ordered doesn't have a true ripstop pattern.

The one I linked is the one I ordered. It has better rated UV than the PU coated variant.

I went with charcoal, which is great because it's pretty much blackout in there. Keeps the sun from waking me up early haha

 

Yea I plan to add some extra bracing and gussets. The main thing I haven’t figured out yet is what trim to use to cover the corners and seams of the new ACP skin. I really don’t like the original trim from the cap. I bought new hurricane hinges for the doors cause mine was beat up.

 

I went with the side ladder as well, it's fantastic. Let me see how you mount it!

 

They make black anodized angle aluminum, would be easy to drill and rivet or use self tappers.

 

Looking good. I still keep eyeing those hurricane hinges. One day

 

I'm impressed!

 

@Sub_Par Do you plan to change the height of your frame? Mine is 23” but I’m thinking about adding a 1/2”. @23” the cab clearance is ~1-1/4”. Seems a little close. But maybe not.

 

I started with a 26” cap, I’d have to measure to see what my heights at now with the roof and supports cut off.

 

Just measured, and I am at 22 1/2” to the upper support. I was hoping to be higher to clear the prinsu rack, because I don’t want to cut it or buy a different rack.

 

Ha I'm taking my sweet time on mine. But would still be down to meet up and see everyone's builds!

 

Selling another set of awning brackets.

Stainless steel CNC laser cut. Used for a few months, but switching to a 270 I'm building.

$50 or $60 if you want me to powder coat them.

 

Consider it sent, I'll take em.

Just out of curiosity, do you have your own powder coating setup?

 

Yes I have a powder coating setup, just a HF one and a toaster oven. It works surprisingly well, even the HF powder is pretty decent. I'm using prismatic powders though, they work even better.

 

Ever get the video finished or interior pictures?

 

Progress is slow but the tubing is fitted up. Just need to double check everything before burning it in.

 

This phase of fab made me want a satellite welding table. lol.
Looking good!

 

I think you're the first to use sharp edge tubing! Glad to see another guy using aluminum!

What's the small frame on the sides for?

 

I'm usually using steel tubing w/ radiused edges. The sharp edges is pretty nice! This is the first project welding aluminum. Picking up TIG welding has been interesting.

The small framed out section on the sides is for the side door. I'm reusing sections from my A.R.E. DCU contractors cap. The original plan was to just modify the roof to mount the tent, but it spiraled into pretty much rebuilding the whole frame. But I'll reuse the side and rear doors. Everything else will pretty much be rebuilt.