How to: DIY Wedge Camper

Can anyone mill me the triple outside corner gussets? I am happy to pay for your service if so.

 

Jumping in late to the party here, but I want to start this project over the winter I think. Tired of the insecurity of my bedrack setup. I think I'm just making the topper for now, but may add the wedge in the future. I'm completely new to fabricating anything at all but know if I take my time, I can do it. I was wondering if anyone around Raleigh, NC has done this or is maybe planning to? I'm sure I will have a ton of questions along the way and possibly need a bit of help.

 

I bought those Valterra connections after you mentioned them months back, were they the ones that melted? I'm building my heater into a 22" Rigid Tool box.

 

Awesome setup. Thanks for sharing.

 

Just wanted to share this. The EXPED is on sale...

https://www.rei.com/product/171124/exped-deepsleep-mat-75-duo-sleeping-pad

 

Yes, but only the straight ones melted due to how thin the walls are. The 45's and bulkhead connections are nice and thick, no issues.

 

2 years late but I picked up my panels just last week. I got them from SignsByTomorow in Peoria. They were the only company I could find that had the 5x10 sheets available at a reasonable price.

They're not Alupanel by name but they are Dibond sheets which are pretty much the same thing.

 

This is a good deal for someone who is ok with the 3" version of the mattress. The EXPED called out in the build is the 10 (the one shared is a 7.5).

Still a great deal at 50% off - just know it is the 3" version not the 3.9" version.

 

I've had the 3" version for a couple years and LOVE it! Yes, it's an inch thinner than 10. However, it still feels better than probably any other mattress you have tried(except maybe the 10 or 15). Also, the R-value is pretty high!

I will say, the 7.5 does NOT come with any type of pump bag. The 10 comes with a little mushroom-shaped one that helps add extra firmness beyond what the self-inflation offers. You can still just manually blow into the valve, but that introduces moisture(mold) into the mattress and is not recommended by Exped. I purchased their pump bag separately ($30) for this reason.

 

@YamaDirtrider get rid of your Amazon special

 

Okay. Don't think I have any of the straight fittings. Only the bulkhead mounts and the connections to them

 

What did everyone use to cut their alupanel or dibond panels who didn't use a router? I am thinking a jigsaw with a metal / fine blade. Going to be cutting into mine this week.

 

Yeah a fine blade will work just fine. Truly any blade will work, especially with how thin the skin is. I used a track saw with a general wood blade and it was all good. Sometimes if you go too fast on aluminum, a tooth can catch and shift the piece but that’s not really a concern on this material. Just don’t rush it.

 

I should be cutting into mine in the next week or two also. I asked for a small piece from the vendor to test with Jigsaw and can confirm it cut through it like butter. No issues. For the straight cuts, I'm going to use a circular saw with an aluminum blade. That was also recommended by the vendor.

 

I used a table saw with a wood blade. Cut it like butter. I also used a razor blade to cut some of the side panels. That was ok. Table saw was better. Very clean cuts.

 

Hey all, I am planning my version out now. I was reading through this thread awhile back and thought I saw that someone else was considering making just the topper without the integrated wedge. Can anyone post a few pics? I am trying to get an idea of how high above my cab I want to take the topper.

 

To those of you that just built the rooftop tent without the space-frame, what did you use for flooring material?

 

For those with the wedge fully built, have you had issues with bed flex even when you have the bed stiffeners? Hoping to build my own but I off-road frequently and all that weight on the bedsides is a concern.

 

Not that I have noticed. @YamaDirtrider has a DCLB and I have a DCSB, We both wheel our trucks fairly hard and haven't noticed anything. Your CG will get way higher with the wedge, so keep that in mind. Almost rolled the truck a few times getting used to the new CG on a wheeling trip a few months back.

 

Maybe a dumb question, but never had to use one. Any recommendations on rivet guns? Looks like prices vary a lot.