How to: DIY Wedge Camper

I just started my build this week. Im attempting to make the "space frame" out of aluminum square tube. I want the finished product to be as light as possible. This is requireing a few extra aluminum gussets but the frame is coming together nicley. At least nice for somthing im making. Its a bit of a gamble on strength. and yes my shop is filthy and I am ashamed.
but so far it feels really strong.

 

Very cool, what wall thickness are you using?

 

Im using 1/8 for most of the frame and 3/16 for the cross beams that have to hold my weight.

 

Good idea with the reinforcements. My experience with aluminum is if you dont get good penetration and grind them flush, you will get cracking very quicky.
Hopefully you beveled most of the buttwelds you sanded down. I do think those plates will help reduce the stress in the welds though. Nice to see an aluminum version

 

For anyone looking to buy some latches and need the full grip range.
I bought a set of these to check quality vs some other knock offs.

These seem super quality and the locks work as designed. Powdercoat seems pretty ok, few bare spots on the key hole area but not a big deal.

Hope this helps someone

 

Hello all, Im still in the planning stages on my RTT portion for my aluminum Go fast camper. I see that most wedge campers attach the faberic to the inside of the aluminum extrusion even actual GFC. But is seems in my head this would cause water and moisture to pool between the fabric and the extrusion? I have seen some flaps at the base to aid with this issue but they look like they would hinder putting the tent away getting stuck between the clam shell or just taking more time having to stuff things in. Do people have trouble with water intrusion or mildew along the edge with the "standard design or do I need to do some sort of extra thing like the flap. Any other options people have thought of would be appreiciated.

 

I added some additional stiffeners to my side panels bridging the sections of aluminum angle on each side of my latches. The panels are now much more solid. Before the extra stiffener they were deflecting really badly at the latches.

Really happy with how they turned out.

 

Oh that’s awesome.
Definitely going to steal that idea.

 

Noticed the bulb seal on 80/20s site is a good bit cheaper than the McMaster Carr one, same dimensions from what I can see. $1.15 ft vs $1.42

 

This is what I used on all the exposed edges of my panels. Works great!

$47 TRIM-LOK Edge Trim – Fits 3/16” Edge, 17/32” Leg Length, 25’ Length, Black, Pebble Texture – Flexible PVC Edge Protector for Sharp/Rough Surfaces, Easy to Install, 150B2X3/16-25

https://www.amazon.com/Trim-Lok-Edg...d_s_purchase_date=Jun+2020&pd_rd_i=B00NL3ZS6E

 

@jmartin2076 What thickness of panel did you use this on?

 

Moarrrrr tubez.





Also added my movable interior platform. The "track" is made of .125" angle iron and the movable base is all aluminum (1.25" 3/16 thick). This gives an opening that's about 21" or so and can also be moved to over the cab to open up the bed.
I'm going to add some of the grey carpet material people use for sound systems along the bottom of the aluminum so that there's no metal/metal interference between the track and platform.


Really enjoying this project so far. Enjoying the change of pace from being a desk jockey M-F Lol.

 

Feel like you need your own build thread to capture the awesomeness of your work

 

Do you have any pics of your panels with this edge trim?

 

@CayucosTacoma it looks like you went a decent bit taller on your build? How much more?

 

At the apex of the cab it's about 4", might look a bit more than that in the photos because the angle.
3" might be better aesthetically, but who knows.


EDIT: Looked at the CAD model, it’s 3.5”.
Looks pretty good in person and leaves plenty of room for body flex when wheeling. 3” still might’ve been better but I’m happy enough with how it looks.

 

Anyone else have a gap that you can see through the latch like i have or did i get crap i need to return to Amazon so water doesnt leak in?

 

Few things here or there, but it's time to use this puppy to its fullest extent!

 

Got my ottertex fabric samples. Seems nice and the thickness is on par or a touch thicker than my Roofnest tent, which is what I was after. Waterproof backing feels good too. Time to decide on a color and order.

 

Sorry for the delay, haven't been checking the thread. I don't have any close ups but you can zoom in on the picture to see them. I think they look better than bare edges.