How to: DIY Wedge Camper

You can easily follow these instructions and build in 2 separate pieces with some slight variations. 1) Camper shell w/ pop open sides. 2) RTT wedge style.

BTW, I'm going to be embarking on this project in the next few weeks/months and will post my progress when that happens. Exciting!

 

@Ripcord Did you pay much attention to the modular floor system when you looked at the GFCs during your design stage? I was wondering if you have any design recommendations.

I’ve been going through your plans noodling on how to incorporate the modular floor to allow the ceiling to be moved out of the way when setup and more interior living space is needed.

I'm debating between 2 potential options:

1) Mount Panel inside the extrusion by bolting a support plate to the bottom of the extrusion in place of the floor panel and then mounting the honeycomb panel to that. I'm thinking with something like 1/8" flat bar this could function like the poor man's version of GFC's custom extrusion.

Pros:

• no need to treat exposed edges of honeycomb panels
• could potentially use multiple sheets of honeycomb instead of one large one (cheaper)
• Does not make wedge any taller when closed
• Allows full wall to wall panel sections to be removed
• Potentially simpler to build

Cons:

• Heavier - extra parts
• Not necessarily taking full advantage of the strength/stiffness of the honeycomb panels in supporting the structure - maybe not necessary?
• Reduces interior storage space for bedding in wedge when closed

obviously this is oversimplified powerpoint CAD but it gets the idea across

2) Mount panel outside the extrusion like Ripcord did. Cut each edge slightly undersized to account for an edge treatment and then bond an appropriate size flat aluminum extrusion around the outside edges to close up honeycomb.

Pros:

• Honeycomb directly fastened to extrusion taking full advantage of its strength and stiffness - maybe negligible?
• fewer parts/lighter weight
• Does not reduce storage for bedding

Cons

• Single large piece of honeycomb required
• Edge treatment could be tedious to apply
• Makes wedge taller when closed
• Smaller sized sections (width wise) would be removable due to leaving honeycomb attached to extrusion at outer edges for structure

I presume they use an extrusion along the edges of the honeycomb similar to this one to enable the panels to pop in and out?

Also does anybody know what thickness Honeycomb GFC uses for the floor? I thought I read 1 inch somewhere but I can't find it again.

 

I intentionally avoided the modular floor, but here is another thread where someone made a wedge camper with a lifting floor similar to the AT summit camper.

https://www.tacomaworld.com/threads/so-you-want-to-build-a-wedge-camper.621150/

 

I can understand why... I keep trying to talk myself out of it hahaha.

Thanks for the link! I'll do some reading.

 

But to answer your question, I would go with method 1 from your post.

 

Thanks, that's the direction I was leaning anyway for many reasons.

 

So bookmarking this for later

 

Did anyone ever hit ya up to help build.

 

I beleive that GoFast has a custom extrusion that has a slot for the honeycomb, thus hiding the raw edge.

 

I designed mine on Catia. My floor will slide forward so the family can be in side if weather is bad. I also plan on using a blowup mattress to save weight and have more room when lid is closed for blankets and pillows. Also will help with mold.

 

Correct, their extrusion has a flange at the bottom that allows the honeycomb to sit within the extrusion. Their extrusion is also a tad lighter than 80/20 per unit length.

That's the beauty of DIY! You can change whatever you want.

 

Currently just starting out my build, I noticed that the mattress is 52" wide however the topper is only 50". is the mattress just squeezed in?

 

yup! holds it nice and snug. The mattress isnt quite 52" wide, so if the camper was 52" it would be a bit loose.

 

Quarantine day 1. Installed the latches!

 

Is that wood?

 

@Beater_Bimmer it is aluminum core honeycomb with a fiberglass sheeting.

 

Thanks for the reply Ripcord, another question for you. Bulb seal, top and bottom or just one side?

Thanks in advance

 

just the bottom

 

Good questions. @Ripcord now that you've been running V2 for a while, any issues with water intrusion (esp. between 80/20 at the corners)?

Also, is there enough positive pressure (with current design) to keep dust at bay?

 

Been dry as a bone so far