How to: DIY Wedge Camper

I was reading through and saw this. If you have a friend with a track saw that will make cutting things straight super nice, especially the hole to get into the camper.

otherwise you can cut aluminum with a high tooth count woodworking blade, if using a sawstop table saw remember to turn off the sensor system or you're out a blade and brake... dont ask me how I know

 

I’ve read the front is slanted a little? What is the reason for that?

I am thinking about making all the sides flat(maybe not the rear).

 

I'm thinking its to match the truck's shape. It'll probably look some like the alucabs with all sides straight.

https://ok4wd.com/media/catalog/product/cache/913c79636509bdc8bbbed930eba3b30f/a/f/af90873e-.jpg

 

The space frame has compound angles to match the cab slant. And if you look the top of the space frame is narrower than the bottom so there will be a natural angle in to meet it plus the forward slant. I don’t like compound miters but I’m going to have to deal with them

 

Got my spaceframe roughed in. 57.25 inches is money! Fits like a glove. Still need to do diagonal supports. I am gonna go for a gas strut lifting floor as well. Will be primarily angle iron for that portion. Going to take some and stitch weld it to the upper square to support the floor and then the floor frame itself will be built out of an angle iron frame



Looking at where the frame buts up against the cab, I think I am gonna do my bulkhead on the inside of the front to give the rear window room and allow me to fit the space frame more snug to the cab. For future reference, 1st gen peeps would be wise to do about 75.5 inches long or so to give the bulkhead more space and not have the spaceframe stick out to far on the back of the truck IMO.



I also am pretty much done with the jig so if anyone in Oregon wants to buy my jig for a 6ft 1st gen taco, hit me up! Save you some time.

 

Awesome. Did you use the same 100" for the 80/20 length?

 

I did. Works great. Only issue I've had is with the cork seal between the frame and 8020. With the amount of rain we get in western WA it is soaking through. I'll probably replace it with something else next summer.

 

Cool. Ah your in western washington. Want to make another one of these hahaha.

 

Not at all But if you need help or advice I'd be happy to. I see your in Seattle, I'm actually south I'm Tacoma.

 

Has it been heavy rains and noticable amounts of bleed through?
I'm debating potentially using something like this if you're having issues under normal conditions.
https://www.mcmaster.com/3949N128/

 

I would use that. I will be changing it to that or something similar. We've had some pretty good rain and when we do I get drips from the bolts going through the frame into the 8020. So watery is getting into the frame. The only other spot I'm getting water intrusion is the the corners where the bulb seal doesn't fit which let's a little water into the tent area. I'm working on that now with something similar to what you posted.

 

I'd go with something like that or a butyl tape and a bead of silicone over the seam, cleaned up so it just fills the void.

I'm in Florida so I am anticipating a lot of water

 

@Ripcord Are your long bed plans work for a 3rd gen?

 

I would think butyl tape would be a cheap and more waterproof alternative to the cork. That and some silicone around the bolt holes.

 

I agree, wish I'd have done that first.

 

Mine don't leak but I'm sure these would in a barn stormer. They do have a gap.
Zim

 

Mine look the same and I don't get enough dust or water through them to worry about.

 

I bought the cheap latches. I noticed some rust already on one of the pins,(the handle pivots on the pin). Good thing is I can replace them later

I've had considerable rain and where the aluminum and cork are joined, I have no problems. BUT...where I had a fabrication issue and the alum did not exactly conform to the gap, it leaked a little. My fault.
Got to remember that cork has held 5 quarts of hot oil in a chevy 350 for decades....ahahahahhaha. My best try at justification. LOL

You should be good.

Yeah I really don't think this design would be completely waterproof. Next build I'll ditch these and go twist handle or T handle.
Zim

 

Ahh, got ya, that and wine bottles . I'm thinking I am just gonna go overkill on the sealing of the two sections as well as any holes in the frame. It does rain and snow here a fair bit at times and I also like to pressure wash my truck and keep it clean lol

 

That would be a very good idea. I built mine in less than 20 working days. There are a few gaps..ahahahahahahaha.
Zim

No leaks here!
But leaks at 2 or 3 corners because the perpendicular tube did not get ground flush. LOL.