DIY 270 Awning for Wedge Camper

So like I said a couple posts back, I resewed the canvas. While it was off the truck, I also redid the connection points at the truck, and am stoked with how it came out. The first corner at the front of the truck is now fastened directly to the front mounting plate (I did have to add some length to the canvas and angle it a bit. The back corner uses a cam strap sewn into the canvas and another strap with a carabiner. I noticed at least a couple other brands use this, and it's amazing. Can attach it pretty slack and snug it nice and taut.

On the perimeter of the canvas, I trimmed with binding, and added some nylon reinforcement at the corners for tie points and grommet support. I was able to get away with one seam down the middle with a 1/2" flat-felled seam by using binding on the edges. I also boxed the ends of the bag - I like how it looks, but the clamshell zipped way easier.

 

Nice work! The redo looks great!

I wish I did the circular cutout in the center to relieve stress. I might end up redoing my canvas on the tent and the awning once it wears a little more. I'll likely end up putting the seam in the same spot as you.

What type of machine did you use to sew?

 

I used an old Singer 600e touch & sew from like the 60's with a #16 Jeans needle and V-69 polyester thread. It barely had enough power to get through the binding edges - I'd have to start it by hand cranking while full-gas on the pedal before it would really go.

The circle cutout seems necessary based on my v1, but I don't think it needs to be very big. I did a 9" diameter circle, and there's a decent amount of slack around it. May be able to get away with a 4" circle.

 

I really want to add one of these to my truck now. It’s much more fun to build these things than buying them

 

Haha, definitely. I was itching for a project, so was happy to remake the shade and camper canvas. But got them done quicker than I thought, and now searching for the next one.

 

I technically havent finished my ripcord camper. I didnt get around to the side doors yet so they dont open with gas struts aaaaand the tent isnt made still. We don't really have anywhere to camp in FL and its always balls hot, I just needed a cool bed topper and this was a fun project, I intend to make the tent and now your awning. It would make for great beach trips and trips to the park with the kid we have coming.

 

Make a fold out shower stall awning.
https://tuffstuffoverland.com/collections/tuff-stuff-overland/products/tuff-stuff®-shower-tent

 

Thanks for the files. I ordered them through SCS, they said the main bracket can't be bend on both sides at 90 degrees. The base must be at least 2x of the sides to fit in their press. I just told them to do 90 on one side, and bend the other side as much as they can.

Other thing I noticed is the file calls for 3 pieces for Intermediate Bracket x3.dxf. I only see 2 pieces needed according to the main 3D step file. Is the extra piece just a spare?
[EDIT, I found your comment on using 3rd intermediate bracket to save SCS cost]

I have another question for you. What thickness did you use with the 3/4in aluminum square tubes? also where did you get them with rounded corners?

Thanks again!

 

Ah dang! I bent mine at home on my press, but if they can get super close to 90 on the second bend you should be able to finish it off with a vise or something. I remember it being tight in my press as well. SendCutSend really needs to invest in some gooseneck dies though, I get that response a lot from them. Unfortunately moving the bend would change the upright tube length that goes in the main bracket, and therefore make the whole thing a lot taller in the bag.

As for the aluminum - everything is 0.125" wall. My local metal shop was able to order radius corner aluminum. It's all 1" square 6061. The sharp corner stuff will likely wear through your fabric pretty fast, unless you manually radius it with a router and corner bit or something.

 

Thank you. One more question. What is spec for the round aluminum tube you used for the pivot?

 

Same as what's in the BoM, only aluminum - 1" x 0.120"

With the bushings you might have to use a burr grinder and hog the aluminum tube out a touch which is no big deal.

 

I got the cut piece from sendcutsend. Looks like they were able to bend both sides exactly 90 degress without any issue.
At least for this piece I received, when they bend it along the 4.156 in lines (supposed to have a 0.125 bending radius), the final width came out to be 4.04 inches instead of 4.25in.
I hesitate to say everyone will have this issue, but do expect variations.

 

Are you taking into account the material thickness and bend allowance? I only ask because I created a part that was bent to a c-channel to fit onto my frame rail that is tapered and it came out SPOT ON from them. I referenced their material charts to get the bend line positioning correct. 1/4" off is pretty significant.

 

I just sent them the file you kindly provided. The lines are 4.156" apart. SCS said bend radius for .187" mild steel is .125". I'm not smart enough to figure out what it means so I told them to just bend along those lines in the drawing.

 

Is the PDF file the for truss arms in order from front to back? (longest one in the back).
I mounted mine based on the CAD drawing (longest arm in the middle), but I don't get square edges that way.
I figured it's easier to ask first before I swap them around.

 

Yeah, the PDF may be misleading - I placed them on the sheet shortest to longest. But the order should be - outboard working toward the camper - shortest, longest, middle length per the image below. But they won't line up at the ends when closed.

But my head hasn't been in the project for a long time, so hopefully that's correct, just based on the model I made everything from. Seems like the directions and measurements have worked out for others as well though so maybe someone else who has completed theirs can chime in.

 

The $55 dollar Rhino-Rack Batwing cover is a good option. I just need to sew a rectangular shape of vinyl to the bag.
See : https://youtu.be/kAa8_IZq-Yg?t=1893 @31min 33sec

I also made 3D printed TPU end caps. The cap seals the opening, gaps the arms so they don't pinch and allows mounting using a zip tie. The file is made for 3/4" square aluminum tubing with 1/8" thick wall.
https://drive.google.com/file/d/1PKjWlrDawGfrvVYH1YTLwxBdxIaf2Ihk/view?usp=drive_link

 

Hey @davzx can you show me some of your upright arms that keep the water from pooling?

I might be redoing mine and wanted to see yours...

 

These are the only photos I have of them.