How to: DIY Wedge Camper

I saw your rig at az wilderness and was snooping on it. Where did you get your panels done? How do you like how you did the floor of the tent? I'm considering doing it like that now... how did you end up doing the floor inside of the tent?

 

Your cuts need to be PERFECTLY straight. If you have a bench sander then you can straighten them out with this and a guide. Best option would be a bandsaw.

 

You can cut aluminum extrusion with a wood blade so long as its carbide tipped, just go slooooow, or obtain an non ferrous materials blade and still go slow.

an abrassive blade will only get gunked up with aluminum. With aluminum you sort of work with it like wood. You sand, not grind. Had someone at the makerspace put a piece of aluminum to a grinder wheel and ruined it because it just loads up on the wheel




side note I just thought of a way to hold the hardware in the extrusion after you pre space it out to mount the roof and anything else. Hot glue, a little drop on either side will keep it in place and is removable if you need to reposition

I might go lazy route and stick the two of them vertically so I have something to bolt mounts onto for gear. Sure its not as structurally efficient as triangular supports but its better than nothing.

 

As others have mentioned, carbide-tipped blade. I used a Diablo non-ferrous blade on my miter saw and cut my extrusion. Cuts through it like butter. Do not use an abrasive blade, you'll have a bad time.

Quite a few have, it's worth reading through the whole thread. Lots of good info has been posted in here.

I modified the plans and just went with a 45 degree angle on the cross supports. Loving all the open room.

 

Thanks for the info guys! Glad I asked.

 

I'm trying find some dimensions/materials for making windows on the front and rear canopy panels. Anyone posted that/got an idea about what page there on?


Buying a partially finished one that I might cut off part of the T weld as part of the sleeping support and weld the 2.5" tracks. That way I can make a modular floor and sit/stand in the bed to get out of the elements a bit more with friends.


So much material love it. Thanks to everyone who has, and still is, contributing.

 

No dimensions have been shared other than overall size of the camper because the plans are a paid set. You can get the plans from ripcords website and he has the patterns for the canopy. If you have a finished canopy but needs windows you can kind of make them as big or as small as you'd like honestly.

 

Cool shit man. I don't have the time or knowledge for a lot of that, so I got a GFC. Yours looks awesome though!

 

I know the dimensions he put up are a paid set, and I'm going to be purchasing them.

I worded by question pretty poorly--too much coffee and excitement. I'm asking about windows on the panels, and the materials used, not super sure how to install windows is the root of my question. Wondering if anyone that has done windows has some good references I could look at online?

Anyone tried using clear boat vinyl for tent windows? Did you go the sewing route or the cement route with those??

Thanks!

 

Decided to test the durability of my composite panel , threw it on concrete floor and stepped on it few times. Probably will have many nasty scratches from tight trails. Has anyone sprayed their panels with bed liner or something similar?

 

@mjshield2 I think the easiest solution would be camper style aluminum framed windows.

 

Whats Up Guys? Long time listener, First Time Caller.
This might be a little long but here is a summary of my notes from my own process so far. FYI this is being fabricated to fit a 6' Bed 2013 Nissan Frontier.

The Latches for the lower panels are called "Compression Latches" and can be found by searching for " RV baggage Compartment Latches" as well.
http://www.rv-project.com/resources/rvsurplus.php has a list of surplus RV suppliers, thats where I found latches. They are upwards of $30 a piece brand new from SouthCo. Surplus is cheaper Obv.

Go Fast Campers is now using what is called a "continuous geared hinge" on their lower panels. They are REAL expensive.

Roof Top Tent Window Rods can be had from www.equipt1.com in Salt Lake City, "Fly Rod from EEZI-AWN 34" Long" also #ARB815121 can be had from multiple retailers.

Windows for the truck cap portion: The ones that are used on the Vagabond Drifter come from a company called StateWide Windows. I got this information straight from one of the owner at Vagabond Outdoors.
StateWide has not/will not return my inquiries.

There is another supplier called Tri-State Windows in the Midwest that also sells RV windows, but they are real expensive as well.

There is a cheaper alternative (which i will likely be doing myself), called a "push on window seal" you can Youtube Install videos. McMaster-Carr #3275T15 @mjshield2

I will be mounting the frame to the truck with "truck toolbox clamps" with custom brackets welded to the bottom tubes. The clamps are available on Amazon.

Here is a SailRite video with a more detailed instruction about installing bug mesh windows around a curve. https://www.youtube.com/watch?v=ofXWtGrAi4k

Below are images of how I built the SpaceFrame, Two mitered corner rectangles aligned with two plumb bobs on center, sitting on a basic frame to hold the two frames at the appropriate height from each other. This gave me more flexibility to match the angles of the frame to the angles of the truck, rather than make a complete jig. I welded the frame in place, on the truck. Hence the blanket to protect from welding spatter. Angles were found with an angle finder, marked with a speed square, and cut with a grinder sporting a cut-off disc.

 

I like what you did there

 

I used Standard size aluminum framed RV windows on my front and rear panels. I bought them from a used RV parts store here for about $100 total.

they are made to fit thicker walls ~1.5” thick so I just trimmed the depth of the frame down closer to the window (I wasn’t able to use the trim rings to secure them) and then installed them into cutouts in my panels with pop rivets through the window flange and panel. I Sealed them with butyl RV window tape.

These aren’t the best pics but are the only ones I have of the windows at the moment. Could take some better ones tomorrow.

first pic is my front panel that’s against the cab

 

Good to know!

You could probably do a nice coat of spray-on liner like Raptor Liner or even roll on. I did roll on in the bed of my truck with Hurculiner and it looks pretty awesome, cant even tell it wasn't sprayed. I would be concerned though with the texture and ability to get it clean. There might be some brands out there that are a little smoother in texture.

Alternatively, car vinyl wrap is fairly cheap for sizes like the doors and would be incredibly easy to install on the panels prior to cutting and drilling and you could protect it that way too. I know they make textured vinyl wraps as well.

 

I was thinking going with vinyl, but still concerned if it gets scratched or start tearing apart....Once aluminum angle is riveted - I doubt I could reapply vinyl...With liner I could possibly just touch it up? Not sure..

 

scratches add character. You can always repaint or re-raptor line

 

My jig is 95% done. I’ll add the wings once I have the top and bottom frames welded can can add the 1” angled support bars. Cost about $80 with a big box of kreg screws. Already had a collection of kreg jig stuff to make the pocket holes. (Mental note move Jerry cans out of garage when welding commences...)




Big clamps for the win.

 

pm inbound

 

Painting question. Brush on, or spray can? Thinking either going with Rust Oleum clean metal primer and professional enamel, or self etching spray primer and professional spray enamel.
Just wondering what people went with and if there is any feedback?
TIA