How to: DIY Wedge Camper

Are you saying any plastic materials on the saw started to melt from the shavings of the steel being cut? https://d.pr/i/ZV6Uzg (screenshot)

 

Yeah exactly, primarily where the lowest arrow is in your attachment - near the pivot point. Just when cutting steel, aluminum doesn't spark so it's not a problem. Aluminum cuts pretty easily if you don't have any experience cutting it.

 

Gotcha, maybe I could make some type of barrier...in the grand scheme of things, doesn't look like there's a LOT of metal cutting...if I destroy it, it's $150, so not terrible....but I'd like to not destroy it lol Thanks!!!!

 

If you're going to do any more metal cutting in the future after this one project, I would recommend one of the Evolution multi material saws. If this is a one time job, then I bet you can make that metabo saw work.

 

Did you just stick it to the flat surface on the top of the extrusion? Did you leave the original bulb seal in place or remove it? Looks like an easy solution if it worked for you.

 

I’m trying to come up with a concept for a slide out bed, like what the pop up campers use. Don’t think you could keep bedding or a mattress on with that as well, but it would make it easier to sleep more people up too.

 

I’m not familiar with that concept.

 

Sad that I'm just now reading this thread. What a terrific build and so well documented! Bravo @Ripcord

 

Really is a great thread. A lot of extremely smart people in here coming up with new innovative ideas to make the wedge better for dumb guys like me

 

I want to know too!

 

I linked to the wrong item on McMaster, but I will use the one I linked if the same things happens again with the inline bulb seal. Here's a picture, this was a more rigid bulb seal and the main reason I wouldn't want to go with it is your extrusions will not be level when it's closed-- not the worst thing, as it allows water to run off rather than pool on the roof. I simply laid it ontop of the bottom extrusion. It worked fine, but beware if you didn't account for this added inch in your tent's rain fly, it will be a pain to close, and can create a channel for water to pool. Hence me breaking mine down to the bones and doing a rebuild. I built this quickly in 2021 anticipating I would find a million thing's I'd rather have after using it for a year and now here we are. The argument that this is more cost effective than just buying a GFC etc has long since sailed, but where the fun in just buying something right?

 

Did you wrap it around the back as well?

 

Which vhb tape did you end using? So glad I found about it after riveting everything together.

 

Yeah it's wrapped around the entire exterior shell of the camper.
Since it comes in 10 foot lengths I split the seam under the rear latch so it's hidden and clean looking still.

 

Question for those that used gussets for the corners - @nanserb & @davzx:

It looks like you both used shorter weld beads only on one side of the gusset instead of covering the whole thing in welds, what is the reasoning here? Or is that just how all gussets get done and I am just clueless?

 

No reason in particular, it's simply that there's a very low amount of possible flex in the frame as is so you don't necessarily need to weld both sides all the way. In the future, if mine were to ever crack I can continue the weld. Since there are people who have made these campers without any sort of braces/gussets in the sides its likely not even needed to have them.

 

For those looking at the rubber strip around the seam where the top/bottom meet up - discountrubberdirect is recommending EPDM and is about $42 for three 10' strips.

I also think that this will work to adhere it: https://amzn.to/3K5zLng

 

I never welded in braces or gussets and it was 100% OK without them. I used the recommended sq steel tubing

 

Thanks for the response - makes sense.

The gussets seemed beneficial as the long bed is dealing with longer unsupported spans. I'm sure it would be fine without, but it seemed like cheap insurance and a nice spot to mount things. Plus I already paid to have them cut.