Aluminum camper pod build thread

[Jonnyo]

I was looking for a small camper that would allow me to go camping in remote location. I was simple and minimalist....

goal: fit F150 5.5 bed
250-300lbs total weight ( to be put on and off the truck with 2-3 friends... to legs
insulated, king size bed
No lose any of my 5.5 cargo box for work/strogage of goods
having fun building another little camper
windows on each side
26X36 teardrop trailer door
Led lighting
39 inch interior height
bed 71x76


So, bought a bunch of aluminum....about 300$ of 1.5X1.5 .039 thickness 6000 series aluminum. that s a very strong and lightweight aluminum tubing. I m tig welding everything together. Will be covered by .04 aluminum sheet, 1.5 inch pink insulation high density board.


Firs step was building a jig on a sheet of wood. This is the shape of the pod.....





Then, start putting the structure together. I have the main side up and missing window frameing and access/cargo door framing. So far so good






the structure weight about 20-25lbs at the moment.... the final frame should be in the 30-35lbs total.....

 

[Jonnyo]

a little test fit to see how it will fit on the truck....

 

[Ambulance_Man]

Really interested to see this progress. I'm taking a similar Alu frame route with the body build on my Defender.

 

[el_topu]

Interesting. Sub'

 

[Jonnyo]

after a month of pause into this build..... as I had a new baby arriving!!!

so, I m now back at it.....day 4! 90% of the frame is done and welded. I just need to finalize window frames on each walls.

now, my main element to sort it is the attachement to the pick up truck box. it will sit on top of the box so on the rails on each side. my question is, how much deflection, flexing those rails of a F150 have during off road/dirt road driving? can I simply make some kind of attachement similar to a fiberlgass canopy? the pod will only wait perhaps 300lbs loaded so it s not a big weight...but I want it to be hold in place safely and hopefully avoid any flexing of the box destroying the aluminum structure? anyone as suggestion or knowledge about truck box flexing?







goal is to be done with this in the next month......weather is starting to improve in BC and I love early spring camping....if I can do a hour or so daily or even just a few cutting/measuring and try to stay on task...I think it s very much doable!

 

[Gunner207]

Great to see you back! And congratulations. Fiberglass or even aluminum truck caps are clamped to the bed side rails and it works. I have never cracked or bent a cap or had the door go out of alignment from off road driving. I would weld aluminum angle on the underside of the pod at the sides and front and then use clamps front and back on each side.

 

[Jonnyo]

frame is done!!!! seems very strong so far!

tried to fit it on the truck

[/URL][/IMG]

[/URL][/IMG]

[/URL][/IMG]

and for some unknown reason....I completely mess up the position of the window that is against the truck rear window. it s a little higher than what I had anticipated. seems like I will need to cut and redo this section!

next step is finalizing the flooring and attachement mechanism..... I need to hurry up....snow is melting and camping season is starting!!!

 

[cheepsk8]

If I read correctly, you're trying to fit a king size bed in a short bed pickup?

 

[Jonnyo]

The exact dimension are 77x 72 so it s shorter than a king but still a decent size for one adult and 2 little kids! A glorified aluminum tent!

 

[Jonnyo]

lots done lately

A flooring done with 1/8 plywood....1.5 rigid insulation board, and another 1/8 plywood. All of it glue together and it make for a very strong and stiff platform. Tested it on the truck and there is no flex.

One of my biggest issue in the past with making trailer is not doing a good job with ceiling panel. i never been able to have then glue nicely with no visiable mechanical faster. So this time, i decided to do the ceiling first. I flit the pod upside down and did the ceiling as if i was gluing a floor...and using gravity as my friend. Let it rest for 24h, turn it back on it s floor and i have a solid glued panel! using polyurethane glue for aluminum to wood is unbelievably strong.

then, it was time to skin the pod using 0.04 aluminum sheet.... and VHB tape to glue the panel to the aluminum frame.

at this point, i m still able to handle the pod by hand so i m guessing it should not be much more than 120-150lbs at the moment. should be able to finish under 300lbs

next step is adding insulation board between all ribs, gluing the inside finishing panels, vinyl wraping the exterior and installing the windows/door...

[/URL]



Received the door from ebay! tried to see if it fit!!! so far so good!

[/URL]

 

[Jonnyo]

productive weekend

roof installed...with a little bit of a curve into it.





installed insulation board. R7.5 in all walls/roof/floor

and cover with 1/8 luan finishing sheet









and after all this, i just realise my biggest opening left is 26X36 (door) and that s all i have to get a king (ish) side mattress inside the pod..... hummm? foam???

 

[Jonnyo]

priming the outside with zinc chromate.....



and i decided to keep it crafty and cheap...rolling rustoleum paint with a foam roller....

Coat #1



it s actually relatively glossy so far..... but will need a good 4-6 coat to get full coverage and uniform tone....

i m using 50% paint, 50% mineral spirit and it lay down very nicely

 

[Jonnyo]

6 coat later.... it s white! i wish i could have painted black to match the truck but living in the Okanagan bc.... it s too hot in the summer to be a dark color. I m trying to think of any accessory that i could add in black color to make the unit a little more matchy with a black F150! any suggestions?




my local sign store made me some vinyl stickers to go on each side. I pick a world map with black dots. I will have some red dots so my kids can add colors everytime we go to a new place!



it took me a good 2h to install those dots. hopefully the other side will go quicker as i m getting the hang of it!




next on the list, 2 more windows to install, A front rack for LED light bar and finishing some interior trims..... i m getting closer!!!

 

[Sixinarow]

Nice job. I'm wanting to build a similar box for a Fuso flatbed.

I see you framed in the windows. Do you suggest doing that or do you think a 1/2" ply outside layer will add enough structure so that I can just cut in the windows later?

 

[Jonnyo]

with 1/2 ply....i dont think you will need any window framing. that said, the framing isnt always there for strenght, depending what will be your insulation and interior panel if you make a sandwitch wall.... it might be better off framing . but if it s a single pane window and a plywood wall, that s definitly duable.