1 Bored Clerk's DIY Camper

[1 Bored Clerk]

All the panels are in place!

Now, just waiting for epoxy to cure. Then lots of routing, sanding and glassing.


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[b dkw1]

So how many rolls of tape have you gone through?

 

[1 Bored Clerk]

Three. Seems like more but that's it.


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[1 Bored Clerk]

Doing a little math, I should be right around 220lbs as it sits right now. I’m hoping to end up (empty) around 350. Sounds reasonable...


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[1 Bored Clerk]

A few camper related things that I haven’t shown yet:

Bulb seals for the door. I couldn’t decide which profile I wanted so I got both. They are adhesive backed which I’m not normally a fan of but they are much less complex to build into the system. We’ll see how they work!

316 stainless piano hinge - 36” long. This will run up one side of the door. Should be good.

Southco latch. Openable and lockable from both sides. I just got one, I hope it’s enough latching for a 42” x 36” door.


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[1 Bored Clerk]

Sanded all of the corners/edges down so they’re ready for routing.

I’ll route all the edges I can then round off all the other edges with my sander and by hand for those really tight pesky areas.

I’ll need to glass all of the edges/corners. The vertical edges will be a little bit of a hassle but I’m mostly worried about the bottom edges. I know you can work with glass upside down but it’s not ideal. Flipping this thing over onto its top doesn’t feel like a reasonable solution either. I’ll have to think on that. I’ll do all the easy stuff first and save the bottom edge for last, I guess.


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[rruff]

Good progress! Probably best to use some silica thickener for the upside down parts.

 

[1 Bored Clerk]

Good progress! Probably best to use some silica thickener for the upside down parts.

That was my thought too. I also happen to have some!


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[Martyinco]

So Awesome!

 

[1 Bored Clerk]

I’ve got all of the upper edges and vertical edges glassed!

These photos only show the upper edges glassed. The other edges being glassed doesn’t make a more compelling picture so I didn’t bother. I’m more than a little messy with the epoxy but it sands off fine and the actual glassed area is squeegied off appropriately.

I didn’t feel like glassing the bottom edges tonight so I decided to lay out the door opening instead. It’s a nice sized opening to crawl through. It’s within 4” of the edge of the panel all the way around. There will be a 2” radius in each corner. I’m hoping that, once backed up with 1/2” plywood for the seal to rest on, that the panel will be plenty stout even with most of it cut out.

I’m excited to see inside this thing!

I’m also going to be visiting Pro-Tech here in Vancouver to get my two aluminum boxes quoted and started (unless they want too much $$$) this week.

Got some quotes on windows as well. Will likely go with Motion windows...also here in Vancouver but their lead time is 8 weeks. Not a huge deal as that’s still January and I have a ton of stuff to do before windows go in. I like the frameless All-Rite windows but they are crazy expensive.


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[rruff]

Looking good!

I'm curious to see what your boxes are like and what they cost. I'd like to see your door/latch details as well. Thanks for the updates!

 

[1 Bored Clerk]

Looking good!

I'm curious to see what your boxes are like and what they cost. I'd like to see your door/latch details as well. Thanks for the updates!

Thanks! Updates are fun for me too as it means I’ve done something substantial. I have a lot of door latch details being worked out in my brain but until I’m a little further along in the actual build of the door, who knows if any of it will work! I’m mostly worried about ‘dry and no rattles’. If I can get there, success will be realized. I’ll definitely post up more details of that process.


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[1 Bored Clerk]

I cut the hole for the door! I’d been looking forward to checking out the interior space for the first time. I’m not disappointed!

I’ve got some cleanup to do on the cut but it’s pretty good. The inside of the camper looks spacious. I’m glad my wife and I decided it would be best to go through the extra work of bumping the ceiling up 6” over the bed area. It would have been a little cavelike with the lower roof. Plus it would have been a less interesting space.


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[Martyinco]

 

[1 Bored Clerk]

That’s just an inch or two shy of a queen mattress in width. I was shooting for queen mattress but I also wanted the camper to be the same width as the truck bed...and have a 1’ deep storage locker on the side. Since I wasn’t stuffing an actual mattress in there, being slightly narrower isn’t a big deal.


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