DIY Offroad Camper Build

[suttonkb]

This build started off as more of an expo build. I wanted something that I could keep the RTT off my truck while on the trails. So I started out by ordering tons of parts that I thought I might need. I went with 6x5.5 hubs to match my toyota lug pattern in case I needed a tire off the trailer in an emergency. I opted to go without brakes since this was just a smaller build that wouldn't weight very much I made my own axle out of some thick tubing my buddy had laying around (welding shop). This build changed along the way and i'll do my best to illustrate how that happened. I am in no way a professional but I find this kind of thing fun. I'm an industrial engineer by trade (imaginary engineer as often called) but still enjoy working with my hands as much as possible. This is definitely a learning experience for me.

Big chunk of parts ordered.


Skipped through the boring part of laying out the framework. Got it rolling with some old tires / wheels off of another truck of mine. These are 35" MTRs that should give me some good ground clearance. I used some old CJ5 springs with an AAL. Shocks were undecided here but knew I was going with some smaller trailer shocks. All this was to keep cost low. I wanted to go with the axle-less timbren stuff but this whole suspension setup probably cost me close to $140 so I can't complain there.


After this we set forth to getting it usable with the RTT. Custom made fenders with two door cutouts for storage access. The footprint was 5'x7' with around 30" of vertical storage inside. This was also setup to have drawers as shown with the cutouts.






After using the trailer like this for a trip in the southeast, I realized that sleeping without any type of AC in this hot / humid area is less than ideal. So for what I sold the tent for, I thought I could convert this thing into something decent to sleep inside. So I started drawing it out on AutoCad trying to put down what I had in my head.



This is roughly what I was wanting. It would involve raising the top to a height where I could comfortably sit up with enough headroom. I knew I would have a 4-5" foam mattress and marine grade plywood to account for as well. I also needed to increase the door size and extend the back in order to give myself a kitchen area.
So I started cutting up and adding to what I already had.

 

[suttonkb]

Once I got the bracing and framing like I wanted it was time to sand and paint. Here's some shots of the trailer behind the 4runner and from above.




After a ton of sanding I was left with this. Shortly thereafter, I set out to paint the whole thing with something to keep the rust down while working on the rest of the project.
I sprayed it with some spraycan krylon fusion black.







Here you can see the 80 series that will be towing this thing to the trails. I love the cruiser but it definitely needs an LS swap. 314k miles on an inline 6 feels like 100 hp..

Once I had the paint done, I was ready to see this thing look like a camper. I went and bought some sheets of marine grade plywood for the bottom. I started laying it out and screwing it down.






Once I got the inside down, I was given some free OSB to work with for the walls. I wasnt worried how pretty this would be since both sides would soon be covered anyways.

 

[suttonkb]

Once the walls were up, I started out insulating everything with 1" foam. I left window openings for installing some prefabbed windows later on.






Once I got all the insulation in place I did some initial wiring since the next step was the exterior sheeting. Once this was done I took the camper to a local fab guy that slapped on all the exterior aluminum for me. He's done this before and I didn't want to take a chance with any leaks. This is where it all started to come together.







I believe there are around 18 tubes of caulking on this thing, keeping it as water tight as possible.

Once I got it back I started with the final steps to get this thing finished. I added a box to the front for the optima yellow tops. I initially started with 3 but decided that might be a little overkill. I used an RV style converter for the wiring. I can plug the camper into shore power when available (or generator) and use the batteries for the 12v fan / other 12v accessories when in the boonies.


I also got the inside painted up with some paint to keep the osb dust down and to add an extra layer of moisture protection.


Here you can see the 12v fan and one of the windows installed. The back does not have the bulkhead installed yet for the AC unit / wiring / kitchen.

 

[stomperxj]

Lookin really good How's the tongue weight on it?

 

[suttonkb]

This shows the back kitchen area without the bulkhead. This will soon be closed off to separate the sleeping area from the back (kitchen area).

I got a 6k btu window unit setup inside as well as the walls carpeted for some extra insulation and noise barrier.




A shelf with some 12v charging still needs to be added here. For the time being I just charge my phone using a wall charger and the plug the AC unit uses.




Back of the WFCO converter. This will be covered with something to allow access but still have a clean look.



Front side showing some of my switches, shore power plug in, and another AC outlet for some just in case type stuff.


I have also added some 12v interior lighting that is pretty neat. It's the RGB LED rope mounted along the top seam of the room / walls. Provides a great amount of light and can even be used for setting the mood haha



These are all the pictures I have for now. Some things still on the list to complete are below.

Finish kitchen area
Vent AC unit outside with kitchen area closed (unsure how to do this currently, ideas area welcomed)
Cut hole in side of kitchen area and mount the cord hatch so that I can close up the rear with the trailer plugged in.
Add shelving inside with 12v charging
Add curtains for privacy
Build new door (current door was pieced together using the old expo trailer door and doesnt form a tight enough seal)
Add cabinets to back kitchen area for cleaner look
Add lighting all around the outside
Add brakes in the future (still need to get it weighed)

 

[suttonkb]

Lookin really good How's the tongue weight on it?

tongue weight is good now that I added the batteries and extended the tongue by a bit. I was worried about that when I extended the rear 1.5' but it came out okay. Ideally I would have liked to move the axle back some but it still came out okay.

 

[suttonkb]

Here's the lighting inside. Guess I could throw a small rave if needed.

 

[suttonkb]