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How to: DIY Wedge Camper

Discussion in 'Tonneau Covers, Caps and Shells' started by Ripcord, Apr 15, 2019.

  1. Apr 15, 2019 at 9:43 AM
    #21
    GHOST SHIP

    GHOST SHIP hates you.

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    Awesome work! :thumbsup:

    My suggestions to address your two concerns:
    1. Bedrail caps from KB Voodoo:

    http://www.kbvoodoo.com/shop/powder-coated-bed-side-rail-cap-system-fits-years-2005-2015

    2. A small "roof rack" that only utilizes the two front mounting points. This could be a simple platform or basket to store gear, but more importantly it would be a perfect place to mount a fairing without looking out of place aesthetically. You could just build a simple fairing with some standoffs to mount to the slots at the front of the camper's leading edge, but IMO that would looked like an after-thought, design-wise. Either way, it would be a simple project for your skillset.
     
  2. Apr 15, 2019 at 9:47 AM
    #22
    Brooksie

    Brooksie Well-Known Member

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    Great build. Great detail. Looks awesome!!!!
     
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  3. Apr 15, 2019 at 9:48 AM
    #23
    Ripcord

    Ripcord [OP] KM6PIM

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    I like the look of the painted bedside tops, so I will probably just cover those holes from the bottom.

    And I was thinking in the same direction as you for a roof rack using the front 2 roof mounting points. Probably what I will do, thanks!
     
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  4. Apr 15, 2019 at 11:37 AM
    #24
    TRD493

    TRD493 Well-Known Member

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    Or this company (I'm sure there are others), they make some light weight corrugated cores that are strong AF. They even have some with foam sandwiched in between....might be too thick though. Very nice build!
    https://www.laminatorsinc.com/
     
  5. Apr 15, 2019 at 12:04 PM
    #25
    Pyrotech

    Pyrotech Well-Known Member

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    Nicely done...
     
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  6. Apr 15, 2019 at 3:41 PM
    #26
    JerryW

    JerryW Well-Known Member

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    Well done. That turned out great. :thumbsup:

    Have you seen any leaking from the felt seals?
    Seems like they might wick moisture through to the inside. I was thinking the butyl weatherstrip or some double stick foam tape would solve that. Thoughts?
     
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  7. Apr 15, 2019 at 4:35 PM
    #27
    tacomavan

    tacomavan Well-Known Member

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    awesome, you ever consider the flippac-style or is that a bit more challenging from a design/build perspective?
     
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  8. Apr 15, 2019 at 4:39 PM
    #28
    frenchee

    frenchee Favorite Member

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    Wow, that's awesome. Makes me feel bad about myself. I started designing the tubular structure to make my own GFC in 2018 but gave up. Just got an RTT. Damn I'm jealous.
    Good job on the square tubing, when I started I wanted square but was having a hard time with the angles on the top section. Circular is much harder to notch. Well done.
    Jig is badass.
     
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  9. Apr 15, 2019 at 4:44 PM
    #29
    frenchee

    frenchee Favorite Member

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    Yeah, when I was "designing" the space frame the struggle was with getting the angles right on the tubes using square tube. A little trickier than round tubing. So jealous.
     
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  10. Apr 15, 2019 at 4:59 PM
    #30
    frenchee

    frenchee Favorite Member

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    Thanks for sharing the excel sheet, I also put a lot of thought into the seals but you have it all there. Very cool. What do you do for work?
     
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  11. Apr 15, 2019 at 5:31 PM
    #31
    SR-71A

    SR-71A Define "Well-Known Member"

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    Dude.. This is insanely awesome! Probably one of the best DIY / tutorial threads Ive seen on here, and thats saying something. Ill definitely have to bookmark this and re-read it at some point
     
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  12. Apr 15, 2019 at 7:22 PM
    #32
    Ripcord

    Ripcord [OP] KM6PIM

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    Took it through some mild snowing and so far so good. I will keep an eye on them though!
    Also, both of the big areas I am using them (bulkhead-spaceframe & Wedge-spaceframe) are in a spot where water would just be getting into the truck bed area. Which is much less of a concern to me than the tent part.

    I did, but that would definitely be a bit more challenging. Those also take more time to setup, which was not what I wanted.

    Thanks! It was certainly a lot of work, but once I dropped the coin on the materials there was no turning back. And yes square was definitely much easier.

    I lived in that excel sheet for a few months haha. I am a mechanical engineer.

    Wow thank you for that compliment! I do like to make write ups.
     
    Last edited: Apr 16, 2019
  13. Apr 15, 2019 at 7:46 PM
    #33
    frenchee

    frenchee Favorite Member

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    Haha, I was 95% sure about that. I saw the whole DIY and was thinking, this guy has to be an ME especially after seeing the Mcmaster Carr on the spreadsheet.
    I'll have to message you about work out there. Been trying to get a feeler on ME positions out of my area.
     
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  14. Apr 15, 2019 at 8:06 PM
    #34
    Pickeledpigsfeet

    Pickeledpigsfeet Well-Known Member

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    great writeup. Thanks for doing all the hard work, now I am going to make one for my Tundra this summer.
     
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  15. Apr 15, 2019 at 8:20 PM
    #35
    Pickeledpigsfeet

    Pickeledpigsfeet Well-Known Member

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    Did you have a reason for not using aluminum sq tube for the frame?
     
  16. Apr 15, 2019 at 8:22 PM
    #36
    Ripcord

    Ripcord [OP] KM6PIM

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    Besides not being able to weld aluminium?

    The spaceframe was only 1/7th of the total weight, so there are other areas I could have spent more for more weight loss value.
     
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  17. Apr 15, 2019 at 8:58 PM
    #37
    Ripcord

    Ripcord [OP] KM6PIM

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    there's lots out here, especially in the aerospace and tech industry
     
  18. Apr 15, 2019 at 9:14 PM
    #38
    foxrcing07

    foxrcing07 KO7FOX

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    Sub’d for build ideas
     
  19. Apr 16, 2019 at 2:00 AM
    #39
    dskakie

    dskakie Well-Known Member

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    Great thread man! I’ve been following along on your IG for the teasers but the final product and this thread blow those out of the water. Super clean work, stoked to see where it takes you this summer! :thumbsup:
     
  20. Apr 16, 2019 at 6:47 AM
    #40
    Ripcord

    Ripcord [OP] KM6PIM

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    Thanks! I am super happy with how it came out!

    I could still see myself making a V2 next winter, but this will be great for the summer.
     

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