How to: DIY Wedge Camper

Got my brackets from OSH Cut. They cut and bent them. Worked out to $20 each shipped. More you order the cheaper it gets.
Send cut send would cut them but not bend them because of them not fitting their bend guidelines but OSH made it happen

 

For anyone looking for clamping ideas, I got these off Amazon and am borrowing the leftover 1.5” square tube idea from whoever did it before in this thread. I feel like it adds a little clamping force which should be nice for helping keep out water I’d think. These were 28 a set so about 60 bucks to clamp down if you don’t have ability to make Ripcord’s brackets and don’t want to spend 120-160 for someone else to make them

 

Sorry, I thought I included that. Guess not.

The hinge: part #1658A16 , Qty. 3, Length 6'

There are beefier options, but I picked the ones I picked based on price, relative to their dimensions. In a perfect world I would have used 316 Stainless and a longer hinge leaf, but the price almost doubles if I remember right. There are also options for piano hinges that have a clearance when they're closed, specifically to accommodate a seal, but again... $$$ you know.

 

Anyone have any ideas about mechanism to lock the back hatch from the inside?

I know some folks have made retrofits for the GFC (and they added this feature in their V2 camper).

I guess could make a version of this to go to the space frame (instead of where GFC as this little tab)

 

Anyone trying to make a covering for the opening in the tent floor, I used the section cutout from the floor and add a trim piece around it. It seems to work really well and actually fits in the 8020 slots.


Also, struggling with some water leaks around the doors. Used some of the left over cork to make the seal a little tighter. Will go with a bigger bulb seal at some point, but seemed to be a good temp fix.

 

Doors about done. just need to mount some of the seals and gas struts.
Had to get creative with the aluminum angle since I used 1.5” tube all the way around. Panels are super stiff and work great with the gas struts.

Not looking forward to the tent sewing portion, hoping it turns out alright.
Edit:
Hand cutting all the panels and river holes suck. If you have the option to get it cut on a CNC router I’d recommend it. Definitely worth saying the time vs cost.

 

Here is my progress. Originally Wanted to build a camper similar to GFC new canopy, found this thread that was really helpful. I am by no means a fabricator or experienced DIYer, but always take on project above my skill level. After 4 months of work and pure frustration, I can finally say - it's almost done. Water still leaks at the hinges location, need to figure out what kind of seal to add or something....Any ideas? The only thing left is to throw on my GFC Superlite when it arrives in April.
Will be posting more photos after adjustments in my insta @eltaco3g

Roof rack rails have been designed in fusion360, purchased Tnutz extrusion bars same as Prinsu ones, added 6x Sherpa equipment Co mounting feet (each is 100lb dynamic weight capacity). Pretty happy with the results

Thanks all!

 

I like what you did with the door for flex. I bet they are very sturdy.

 

Do y'all have any tips for lining up the t-nuts when attaching the spaceframe to the aluminum extrusion, sandwiching the composite panels?

I'm thinking about pre-loading the bolts with the nuts and then trying to slide the extrusions down the line so that I'm not hunting in the dark.

I'm talking about this part, as seen in @Jarman02's VERY helpful walkthrough video

 

I doubt you will be able to slide the extrusion. Not with that many slot nuts and bolts.

Just take the floor panel and set it on the extrusion and line up the holes and slot nuts and then set the space frame on and line that up and youll be 95% there.


Water leaking around the hinges is STILL something I havent been able to get sorted, even with a thicker bulb seal. The leaking isnt super bad or anything, but it bothers me lol. I am wondering if putting the bulb seal on the frame instead of the door would make a difference. Not that I want to since removinf adhesive from the door panels is vastly easier than the paint of the frame.

Went to the dunes this weekend and all the doors are sealed pretty well against that. The only issue with the design of this camper and other similar ones without a door sill is that dust and water gathers on the top of the door seals and then falls inside when you open the door. If I can solve for that, Ill be a happy camper lol.

 

I haven't done that part yet, But I had exactly the same thought, to slide the extrusions onto the frame with the T-Nutz already in the frame. I ordered some plastic horseshoe shims from mcmaster awhile back, to aid in such pursuits. They're just handy to have around anyway. I'll let you know how it goes.

 

big baller using genuine southco latches.. Niceeeeeee

I like the door stiffener method you used. Did you lay out the holes and CNC them out?

 

How are you liking the tube version? Do all the seals sit against the round faces well? Wish you had done square?

I'm considering round aluminum.

 

You might try a piano hinge like @NotTaco posted. They fairly cheap on McMaster and that should overall help the falling in problem and some of the water. Another member also suggested attached the 600d canvas around a piano hinge with a small layer of rtv as it should make a nice water/dust proof layer

 

I love the look of it. Made the top portion square so it seals against the aluminum extrusion better; also for the hinges to mount on.

Square tube would’ve made fabrication a lot easier but if you’re up to the task then I see no issue.

As far as sealing goes, I used double bulb seals on everything so it seals on the inside face and outside face. Round aluminum would be rad, cut down weight which is rad.

Round looks better IMO, but a real pain to work with compared to square. Kinda up to you if the look is worth the extra work. Lol

 

Still needs some fine tuning, but it’s getting closer

 

Thats REAL SICK!

 

Hope I didn't miss them somewhere but I would be very interested in these dimensions as well! I love my camper but suffer from the same issue being 6'6", I sleep with my head against the roof and my feet hanging off the end of the mattress, ended up just about as cramped as when I was sleeping in the bed of the truck before. Would be worth modifying the canvas for sure!

 

I have not posted the dimensions for the hinge yet, still working thru some stuff once I’m happy with it I will share

 

Much appreciated!