How to: DIY Wedge Camper

It’s most likely twisting because you don’t have the inside corner brackets as well. They add a lot of strength and resist the twisting you’re experiencing.

 

Making progress. It’s taken way longer than I’d hoped, but family and work always gets in the way haha. Just need to cut out and sew the windows and the tent is done. My lift arms need a little tweaking as well but it works for now. Getting really excited to get this thing out for a maiden voyage, but trying not to cut corners just to finish it.

 

Mine had similar gaps. I just cut up a plastic file folder into "L" shaped pieces that covered the gap and double stick taped them to the top of the extrusion. I have a drip flap around the perimeter of my tent base so it covers most of the gap filling plastic. Here's a crude drawing of what I cut out:

Do you have any pictures of your lift mechanism inside? I'm seriously considering reworking my camper to a full pop because at 6'3" with size 14 feet there is very little foot room at the base of the wedge. It's fine when I'm by myself because I can lay diagonal but it gets pretty cramped on trips with my wife.

 

I’ll take some when I remove the tent. They are pretty basic as it was just to get the concept to work. I plan on making or buying some beefier hinges and I need to redo the arms to make more room for the tent material.

 

@plurpimpin

 

I'm planning on sewing on a skirt that will bridge the gap between the fabric and the frame.

 

About 90% done, but couldn't wait anymore for a good shake down!

 

thanks that helps a lot! You have one on each end, right? Also what size/length gas struts are you using?

 

Yes one set on either end. I am using 36” 40lb struts which are not the correct length for my 30” opening but I made it work by spacing them down with brackets. I wanted to have 36” inside height because I’m 6’2” and wanted to be able to sit up in bed. Ideally I’d have a 38-40” but I couldn’t find them without going custom for about 90 per strut. I kinda guessed on the lbs needed, and right now the roof closes but it’s a two person job, so I am hoping they break in a bit with use or I’m gonna need some 30lbers.

 

@plurpimpin I did a full pop also and was able to find the 40" struts that Four Wheel Campers uses. They are made to order so they took about 4 weeks to get.

20lbs 40" https://shop.suspa.com/c16-31895a-gas-spring-p5207.aspx

30lbs 40" https://shop.suspa.com/c16-31896a-gas-spring-p5209.aspx

40lbs 40" https://shop.suspa.com/c16-32561-gas-spring-p5201.aspx

50lbs 40" https://shop.suspa.com/c16-32615-gas-spring-p5351.aspx

60lbs 40" https://shop.suspa.com/c16-34442gas-spring-p5352.aspx


Also Lift Support Depot has a few over 40" as well but I didn't find out about them until after I had already ordered the Suspa ones.

https://www.liftsupportsdepot.com/c...eturn=all&Customfieldextendedlengthain=40||45

As a side note, I originally bought some generic 36" long ones on Amazon (non-Suspa ones) and compared them to the USA made Suspa's and there was a huge difference in quality. The shafts were the same diameter but flexed super bad and just felt very weak.

 

Curious as I begin prepping for my build. Are there any tools you had on hand or bought ahead of time that made the project substantially easier or more professional looking? Or even some hacks for any of the processes that hadn’t been mentioned prior which saved you time.

 

Any pictures of your setup? What lb springs did you use? I found some of those as well but they’ve been on backorder for half a year.

 

I'm not using any 8020 so mine is kinda different. I guess this is the only picture I have of the roof set up. In this picture only one of the lifting mechanism was done. Right now the frame is done and I'm almost done putting all the exterior panels on. I went with 40lbs struts. I'm anticipating my roofing being about 90lbs with the steel frame, maxmetal, fan, and roof rack tracks. The ones I linked say backorder but really are just made to order I didn't realize that until I reached out to Suspa.

 

Not using 80/20 is a great way to keep the cost down.

 

We’ve been enjoying our DIY wedge! There are still a few additions planned such as a removable tent back to cover up an open tailgate and hatch, mounting the fold down 24x72” box bed and a new 12v fridge!

 

I'm digging that electrical panel setup you got there. Got any more pics?

 

I'm selling my camper! Figured I'd post it here first. It has 100 watt renorgy solar, 8020 rack, and four driving lights. The bed platform slides over the top of the cab. Looking to get 5k obo. Currently in Reno, NV willing to drive a bit.

 

Location would probably help the sale.

 

Thanks!

 

Here are a couple I have handy!