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Couldn't you just treat the plug in the bed as the "car battery" side? Will the wire be large enough to handle 50A? (I'd think it would need to be at least 6awg.) Look at the Redarc BCDC1225. Very similar, but seems more rugged and only puts out 25A. Looks like 8awg would do it.

When I bought my Northstar it had a beat up bottom too. We took the old stuff off, re-insulated and then put a new plywood bottom on that was thicker. I sealed the whole thing with a coat of epoxy I had leftover from another project. It still looks new as we have a rubber horse pen liner in the...

With the hard side (which was both taller and heavier) we would average 9-10mpg (diesel). The pop-up gets 12-13mpg and I drive it faster because it feels ok to do so. I have seen 14+ on 45-55mph back roads. Truck gets 15-16 unloaded.

My Northstar (not the same I know) has a nice arch to the roof. Surprising for a 20 year old popup. I've had a few rubber roofed RVs. I didn't like how easy they tear if you happen to go under a tree branch hanging in the road. Might not be as much of an issue on the shorter pop-up vs a...

I had a '17 F-350. I don't think you will have any issues as long as you drive at reasonable speeds for that setup. Mine grossed out a little over 20k lbs and the truck did fine other than the built in Ford bump steer when you hit bridge seams at speed. Those will wake you up!!

Closest I’ve seen is North Star has a side pop out bed on one of their models.

Fellow TC800 owner here. Mine is a 2000. The roof is in ok condition. One corner has been dented and repaired poorly so I will be repairing it soon. For wood glue the best I have found is Aerodux Resorcinol. It may be overkill for a small project. I’ve had good luck with Titebond 3 for smaller...