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UPDATE I built a rear bumper out of some scrap steel. The Bumper is 1.5x6 inch C-channel and I welded on some 1x2 rectangular tubing to make mounts that bolt onto the stock bumper mounting points. I notched the ends and bent the face of the C-channel around the notches to create a curve on...

Yeah, I'm happy to finally have a box. Now I get to start doing all the other things that make it a camper. I welded mounting points on the camper subframe that bolt to each of the 6 stock bed mounts. I'm thinking 6 circuits. It's probably more than necessary, but I figure I might as well...

The big, accessible storage spaces are something that I feel is missing in every commercially manufactured camper that I'm aware of. And one of the reasons I chose to build my own instead of just cleaning up an old slide in. In our previous camper we traveled with 5 surfboards, a tandem...

UPDATE CONTINUED The bottom of the camper and the floor inside the storage compartments got 2 coats of Hurculiner Bedliner with an extra 2 coats in the wheel wells. And I added a brown stripe for fun. Back to the doors. The storage door on the passenger side and the entry door are mounted...

UPDATE CONTINUED The entry door was given an aluminum trim on the non-hinge edges in the form of T-section with countersunk mounting holes about every 6.5 inches. This trim was attached with #6 flat head screws and adhesive sealant. The large storage area door on the driver side was hung...

UPDATE I built doors for the camper using the same process as I used for the insulated panels in the camper body. (5mm plywood and Douglas fir frame filled with polyurethane pour foam) but I wanted to have a wood edge all the way around instead of leaving one edge as exposed foam, so I cut one...

The 2 forward ones are 80 lbs strength and the rear ones are 60 lbs. This is because the forward ones aren't mounted all the way forward, so they have more weight to deal with on that end. I did not weigh the roof. Based on me trying to move it around I guessed it was over 150 pounds. With the...

I just read through your build. That came out real nice. The 3D printed pieces are cool. Sounds like you got your actuators figured out pretty well and had a good design for their tendency to be out of sync. I read some threads where people just couldn't get them to synch up and they didn't...

Thanks, I'm feeling good about how the seal turned out. I'm sticking with the gas struts. They have plenty of lift and it just seams like a simpler/cheaper system to me. To be fare though, I haven't looked into electric actuators since I originally designed the build over 2 years ago, so there...

Yeah, Ive been at it for 2 years, but hoping to get it usable by the end of the summer. "usable" is the goal for me right now. Ive got too many ideas for little storage compartments and awnings and such to believe it will really be DONE anytime soon?

Thanks. The slides are working well at the moment. They feel like they could prove to be the weak link in the system, but only time will tell. Cant wait to get this thing rolling so I can start the trial runs

UPDATE I used 5 drawer slides mounted in-between the inner and outer pop-up walls to help guide the roof/outer walls as they are lifted or lowered. The slides weren't thick enough to fill the 5/8" gap between the inner and outer walls, so I used a piece of 1.5"x 1/16" aluminum flat bar as a...

Update The roof was built in 3 sections. Each section is my standard 1x2 wood frame, 5mm plywood skins, and filled with polyurethane pour foam. The sections were put in place and attached to the walls and to each other with wood glue and pocket screws. I rounded off the top edge around the...

More info will be coming soon, but here is a link to the drawer slides: https://amzn.to/3Yo7iPq I used 5 of them. And I used 4 gas struts (AKA air struts or lift supports) from this website: https://www.liftsupportsdepot.com They have a bunch to choose from depending on the amount of force you...

UPDATE Yes, this project is back in action. This update is progress on the pop-up! I started by building each of the pop-up wall panels. 4 of the 6 walls are just basic insulated panels like you've seen me make throughout this build with 1x2 wood frames, 5mm plywood skins, polyurethane foam...

Had to put the build on hold for a while, but just got back at it. I hit a few snags with the popup and have slowly been solving issues. If all goes according to (new) plan, I should complete the popup in a couple weeks and will post a full write up after that.

Benjamin Moore got back to me again when I asked for an explanation for why they recommend Acrylic over polyurethane enamel for this application. "Unfortunately, we don't have any testing data for this type of project. I thought it best to use an acrylic for the flexibility reason. Oil based...

Thanks Nopec. Thats a nice texture you achieved. The Monstaliner's texture is a bit more aggressive than I would ideally want anyway.

Benjamin Moore got back to me. They recommended Fresh Start All Purpose Primer 046 and Regal Select Paint. They didn't explain why they thought this would be the best product for my application. The primer and Paint are both 100% acrylic. Apposed to Rust Scat which is a Polyurethane enamel or...

I'm starting to think that this is one of those things I'm putting way too much thought into ? Just roll some paint on there and go camping, right ?!