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I decided to go the EMT conduit route for the lifting mechanisms. Since this photo the entire height from frame to roof has been lowered 2.5" and I realized that there was some unacceptable flexing in the roof frame. I ended up using 2" tall rails on the exterior and 2 that span across the roof...

Some closeups for your viewing pleasure.

I used 1" Aluminum angle to cover all the edges. I placed 2" wide double sided tape to cover the edges and then placed the angle aluminum and trimmed the excess tape. Around all the edges I used a doors and windows sealant.

After all the siding was on I decided to weigh the camper and it weighs in at a svelte 165lbs.

Luckily I work in a high rise building as an engineer so I have access to awesomely large storage rooms to work in. Like I said in the first post I am using 3mm Aluminum Composite Material (ACM). It is being attached with double sided tape. I was skeptical at first, but it seems to be holding...

At some point while waiting on the new 3' tall main support rail I decided to start building the roof frame. My wants is two fans and two solar panels.

So I decided to see what the view was like and contemplate life decisions that lead me here to building my own camper and then having to rebuild it again. When the 1" main rail didn't support the weight at the front i decided to try 2" tall main rail with supports which also didn't fully...

I then started to add in the filler pieces that will strengthen up the camper. It was also at this point that I realized that a 1" tall main support from front to rear was not strong enough.

To attach it to the truck I replaced the factory bed rails with unistrut. I then purchased some Tacoma canopy clamps and modified them to fit into the channel of the 80/20. This is only the first rendition.

Started the frame build. Just doing the outside to see what and how much I need to strengthen it up. At this point the camper is 62" wide.

A view of my 'shop' loaded out with some of the 80/20

Last November I started to plan out a custom built pop top camper. In January I started the build. The following is a collection of pictures and thoughts of my build. So I do not know how to weld very well and I certainly don't know how to weld aluminum. So I decided to do my build with 80/20...

Sent you a PM yesterday.

What is the approximate weight of the trailer and tongue weight? Thanks

looking at the pic i'm going to guess no trailer brakes unless they're super tiny and located in the hub.

FYI Agile off-road just quoted me 16-17k for an 88 E-250