Just an other aluminium truck camper project

rhodos

Observer
Hello everybody,

just want to present my current project - a pickup camper with popup roof and hard side walls, basics are :

aluminium frame - welded, tubes 30 and 60 by 30 mm, 2 mm wall thickness, skin - aluminium sheet metal 1.2 mm, electric system - 300 Watt solar panels, batteries - 100A LiFeYPO4, Katadyn water filter, roof lift with electric driven spindle gear.
Truck : Ford Ranger with 2.5 l 4banger turbo diesel

So now some pics.



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first drawing
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start welding

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growing

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first fitting test


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lower frame (nearly) finished

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unfinished upper frame

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lift mechanism with end switch

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batterie box

so much for today, I will post more pics and text as the project continues.

bye Werner
 

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Last edited:

The Artisan

Adventurer
Cool to see you are doing a screw drive system. I have a design planned for a lifting roof using the same technology.
Kevin
 

guidolyons

Addicted to Gear Oil
Ausgezeichnet!
Alright, that does it for my German vocabulary.

Nice job Werner, Looks interesting, keep adding photos.

You can insert the photos
914_IMG_1095.jpg

Like this so it is easier to read
914_IMG_1084.jpg
 

rhodos

Observer
thx for the friendly comments, forgot to mention one spindle drive pushes 330 pound at 8 Amp, the motors are rated at 9 amp continous and 30 amp short term!
 

rhodos

Observer
Here some progress - slow but steady ;-)

first a rolling "chassis" for loading and unloading the camper

IMG_1503.jpg

IMG_1504.jpg

start gluing the sheet metal to the frame

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bye Werner
 
Last edited:
What are you using for insulation? 2.5 TD Ranger? If i recall, Ford offered a diesel in the Ranger for a year or maybe two in the mid 80's. I think they were like a 2.2 with no turbo. Very slow and no one bought them. Your truck looks much newer than those ones, and with the turbo, should handle your camper fine.
 

rhodos

Observer
Insulation will be XPS aka Styrofoam or Styrodur - 30 and 40 mm, inner walls on the upper lid from Forex (Hard PVC Foam), lower part marine grade plywood. Our Ranger has a 2.5l Turbodiesel, those models are not sold in the US but are very popular here in Europe - 140 HP and lots of torque.
 

rhodos

Observer
again some pic on the slow progress - upper part is finished and here we go : cutting sheetmetal, bend and glue it to the main frame:

IMG_1594.jpg

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IMG_1553.jpg
 

rhodos

Observer
and again some new pics:


door hinge - Tilaband

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first test

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door

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frame for service door

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beside the LiYFePO4 batterie, the water filter and the Shurflowpumpe this box will house the electronics and a 12V compressor

IMG_1613.JPG
 

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