Roof top tent - DIY - Scratch build

balu4k

Adventurer
Decided to do my own roof top tent from scratch. Collected ideas from various posts around and little more thought process and started with this build. Thanks for those who shared their build which helps me with this build. I am going work not more then 5 to 6 hrs per week. so this is going to be very slow build. I will keep posting it as when I progress.

This RTT will be mounted on our Sequoia for now and later will be building a Off road trailer and this will be used on the trailer.

I love doing works like this and my intention is not really to save money but yes if there is an option to save by doing instead of buying I will :)

Here is the parts list I thought of as of now and approximate cost what it would be.

Parts ( will keep updating as and when I buy )

Heavy Duty Canvas Tarp ( ~ 150$)
mesh for windows (~ $20)
zips (~ $20)
Velcro (~ $10)
rain flies (~ $40)
Foam Mattress


plywood (~ $100)
Hinge - ~ $20
Condit tube, elbow and connectors( ~ $30)
hardware (~ $100)
ladder (~ $50)
Travel Cover (~ 20)
1" tube to mount on the roof. (~ 20$)

Specification:

Size: Open - 6' x 8' x 4'
Size: Closed - 6' x 4' x 15"


Step 1: Hinges.

was looking for the hinge which pivots at 2.5" high and was not able to find any of that kind in HD. tried few other ideas using Flat L bracket but it did not work much so finally decide to make one using 2" width and 1/8 " thick flat metal and normal L brackets. this then materials costed roughly around $10. I don't have a welding and hence decided to bolt it together. will keep checking for it snugness and will decide later if it needs to be welded.


Step 2: Ideally I should have started with plywood but its raining out side so I decided to pick them up from lumber yard sometime in next couple of days when its not raining. so I skipped that and went a head and started cutting condits tube.

Stopped here today. will update once in progress.


Comments and suggestion welcome.
Also Experts let me know if I am doing anything wrong. would love to correct it.

Here are the few pics.

Open Position:
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Close Position:
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Tent Tubes arrangement:
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John E Davies

Adventurer
Cool, this will be fun to watch.

Might I suggest going larger on the pivot bolts, and installing sintered bronze (self lubricating) bushings? They are porous and absorb the lube, releasing it as needed. The larger diameter reduces wear on the bolt - I expect that is a pretty high stress area when the tent is occupied. These are a little too long, but they are easily sawed and filed to the correct dimension.

51eykz9-j9L._SL500_AA300_.jpg

http://www.amazon.com/Bunting-Bearings-FF520-10-Thickness-Powdered/dp/B0040JG3SK/ref=sr_1_1?s=industrial&ie=UTF8&qid=1361817826&sr=1-1&keywords=bronze+bearing+3%2F8+bore

Your local bearing house will have this stuff in stock.

Be sure to add a large area, thin stainless shim or fender washer between the two moving sections, or the paint will wear away fast from chafing. If you don't want to bother with bushings, then for sure use stainless hardware for the pivot bolts, or they will rust.

Good luck on your project!

John Davies
Spokane WA USA
 
Last edited:

4xdog

Explorer
Isn't there some old Popular Mechanics / Mechanix Illustrated or similar article from the 50s out there someplace providing plans for a home made RTT? I can almost see the pictures in my mind. It's been talked about on ExPo IIRC. Maybe available on Google Books, where a lot of those back issues live.

There might be some ideas there. As Ralph Waldo Emerson said, "all my best thoughts were stolen by the ancients".

Don
 

balu4k

Adventurer
Todays update..

Thanks guys for the suggestion and guidance. Today i got a chance to run to lumber yard to pick up the Marine quality plywood for about $70 two 4 x 8 3/4" thickness, got them home, cut them to 4 x 6 's and assembled all the poles and the hinges.

Next step is to order the vinyl fabric and wait for it. while waiting for it to arrive i will sand this plywood and treat it with some water sealant.
Also purchase some aluminum trims for the edges and also paint the plywood in white to look professional ? haven't decided yet. mean while here are the pics of todays work.

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