2020 Ram 5500 DIY Composite Panel Camper Build Thread

RAM5500 CAMPERTHING

OG Portal Member #183
Here are some answers to the same questions i keep getting over and over on Instagram and YouTube:

WINDOWS: Yes, i am installing windows. But, they are fairly low on the priority list, and wont even be ordered until i finalize my exact layout, so they are the perfect size, and fit in the perfect position

PASS THROUGH: No, it wasn't even a consideration at any point. I know this is a hot topic, but i see zero need for one, and dont understand all the hype. That and I'm 6'4" 285lbs and would need one hell of a hole to get through it. I also have zero interest in cutting a giant hole in a brand new truck and essentially killing the resale value if i ever decide to separate truck and camper.

DEPARTURE ANGLE: "Why didnt you do a departure angle to get more interior space?" I have been asked this many times, and the answer is still the same. They simply don't make sense TO ME. I'd say 75% of the rigs out there with the Dep Angles have awkard bumpers or racks mounted to them, essentially defeating the entire purpose of them in the first place. Also, i live in California, which is home to some of the worst drivers on the planet, and i wanted maximum protection for the habitat. Meaning, i wanted a nice huge beefy rear bumper protecting the entire rear end of the box. It is almost impossible to drive on CA freeways for more than an hour and NOT see a rear end collision. I notice most folks with "departure angles" have very little, if any, protection for the box in the event of a rear end collision. For each is own, but i dont understand it. Standard square box with protruding rear bumper also makes towing or carrying mountain bikes a ton easier.

INTERIOR: I have some basic layouts in my head, but my main focus now is finishing up the last little bits on the outside, and getting the rig to my house. I will be doing most of the interior build out with 80/20 extrusions.

WEIGHT: I am just as curious as everyone else, and will be weighing it ASAP once its drive-able, probably later this week
 

180out

Well-known member
mine is 17K and some change when it is all wet and ready to go, everyone gasps when they hear that and say OMG cant take it anywhere. i have had zero issues going anywhere. we spend as much time as possible on dirt roads. driven 1000s of them with no issues. i would say the weight helps more then anything. i still run good old fashion duel toyos on leaf springs. love that i have 3 spare tires should all go wrong. love your build, good on you for sharing and being your own dog. hope to see you out in the desert soon.
 

DirtWhiskey

Western Dirt Rat
DEPARTURE ANGLE: "Why didnt you do a departure angle to get more interior space?" I have been asked this many times, and the answer is still the same. They simply don't make sense TO ME. I'd say 75% of the rigs out there with the Dep Angles have awkard bumpers or racks mounted to them, essentially defeating the entire purpose of them in the first place. Also, i live in California, which is home to some of the worst drivers on the planet, and i wanted maximum protection for the habitat. Meaning, i wanted a nice huge beefy rear bumper protecting the entire rear end of the box. It is almost impossible to drive on CA freeways for more than an hour and NOT see a rear end collision. I notice most folks with "departure angles" have very little, if any, protection for the box in the event of a rear end collision. For each is own, but i dont understand it. Standard square box with protruding rear bumper also makes towing or carrying mountain bikes a ton easier.

This times 1000X. I've seen these scooped up rears on all of the flatbed builds and it just seems downright unwise for the reasons above. I think it has a lot to do with the whole overland "lifestyle" image cancer that Instagram has created. With that cut rear, all of your rear mounting options push the weight way too high, complicate and lengthen the rear jack position and take away storage space. I've never seen one that the departure angle gained isn't lost to required DOT coverage for the bumper or the hitch.

One of the many reasons I will not being going with FWC for my flatbed build. My main dimemma is that, being who I am and deeply knowing who I am, I will never ever build a masterpiece like this. If I attempted it it would take 10 years. Part of growing up is understanding your limitations. Hehe You, sir are building a dream rig that I cannot. Bundutec, Overland Explorer (currently my first choice), Alaskan and ATC all will build you a flat back. Phoenix too. And they will mostly put things where you want them.
 

rruff

Explorer
...required DOT coverage for the bumper...

Wondering about that... found this:
"The DOT's bumper standard requires impact protection in the region 16 to 20 inches above the driving surface. This requirement applies to passenger cars only. Pickup trucks, SUVs and minivans are not covered because their bumper height varies depending on the clearance they need to operate appropriately."

And this: https://www.semasan.com/semaga/State_Laws_Impacting_Altered_Height_Vehicles.pdf

Most states have no bumper laws, but many do... and it's ~30" max typically.
 

mog

Kodiak Buckaroo
Wondering about that... found this:
"The DOT's bumper standard requires impact protection in the region 16 to 20 inches above the driving surface. This requirement applies to passenger cars only. Pickup trucks, SUVs and minivans are not covered because their bumper height varies depending on the clearance they need to operate appropriately." Most states have no bumper laws, but many do... and it's ~30" max typically.
Depending on the weight classification, 49 CFR § 393.86 - Rear impact guards and rear end protection. might apply.
A lot of European Expo-trucks that have similar regulations have moveable/raiseable underride protection.
I believe the OP (RAM5500 CAMPERTHING) has a rear between the rails fuel tank. If it is similar to my C4500, the requirements of 49 CFR § 393.86 cause no additional burden as the fuel tank needs protection, so two birds (underride and fuel tank protection) with one stone. Even complying with that, BATs (Big A** Tires) certainly help offset that lower protection. The departure angle on my truck with 42s is 34.1°. For reference, a stock F150 Raptor is 22.7°, a Jeep Gladiator is 18.0°, and a Jeep Rubicon is 37.0°
 
Last edited:

RAM5500 CAMPERTHING

OG Portal Member #183
mine is 17K and some change when it is all wet and ready to go, everyone gasps when they hear that and say OMG cant take it anywhere. i have had zero issues going anywhere. we spend as much time as possible on dirt roads. driven 1000s of them with no issues. i would say the weight helps more then anything. i still run good old fashion duel toyos on leaf springs. love that i have 3 spare tires should all go wrong. love your build, good on you for sharing and being your own dog. hope to see you out in the desert soon.

same, always up to meet up with expo folks for beers
 

RAM5500 CAMPERTHING

OG Portal Member #183
This times 1000X. I've seen these scooped up rears on all of the flatbed builds and it just seems downright unwise for the reasons above. I think it has a lot to do with the whole overland "lifestyle" image cancer that Instagram has created. With that cut rear, all of your rear mounting options push the weight way too high, complicate and lengthen the rear jack position and take away storage space. I've never seen one that the departure angle gained isn't lost to required DOT coverage for the bumper or the hitch.

One of the many reasons I will not being going with FWC for my flatbed build. My main dimemma is that, being who I am and deeply knowing who I am, I will never ever build a masterpiece like this. If I attempted it it would take 10 years. Part of growing up is understanding your limitations. Hehe You, sir are building a dream rig that I cannot. Bundutec, Overland Explorer (currently my first choice), Alaskan and ATC all will build you a flat back. Phoenix too. And they will mostly put things where you want them.

Thanks for the kind words. It’s been a lifetime of trial and error figuring out what works, don’t work what I like and don’t like.

All the while ignoring the draw of the Instgramlanders repeatedly copying each other’s mistakes ?
 

RAM5500 CAMPERTHING

OG Portal Member #183
Here is basically the last piece of the puzzle. Dropped them off at powdercoat this morning, and once i get them back and installed the box is DONE!

I wasnt too keen on the sharp tight angles on the stainless corner caps that were supplied, they looked wonky, so i had a friend make me a set to match the radius of the extrusions for a cleaner more streamlined fit, out of aluminum.

I am very fortunate to live in the fabrication mecca of the US and have some super talented friends. He whipped these up with the quickness. THANK YOU JARED

I can build things, rebuild things, and fix things, but i am NOT a fabricator whatsoever. My brain just isn't wired like that.

Supplied Stainless Caps:
cornercapsjared6_FORUM.jpg

New Aluminum Caps:
cornercapsjared5_FORUM.jpg

Comparison Photos:

cornercapsjared3_FORUM.jpg

cornercapsjared4_FORUM.jpg

Test Fit (like a glove):

cornercapsjared_FORUM.jpg

Sanded and ready for powdercoat:

cornercapsjared2_FORUM.jpg
 

andy_b

Well-known member
Here is basically the last piece of the puzzle. Dropped them off at powdercoat this morning, and once i get them back and installed the box is DONE!

I wasnt too keen on the sharp tight angles on the stainless corner caps that were supplied, they looked wonky, so i had a friend make me a set to match the radius of the extrusions for a cleaner more streamlined fit, out of aluminum.

I am very fortunate to live in the fabrication mecca of the US and have some super talented friends. He whipped these up with the quickness. THANK YOU JARED

I can build things, rebuild things, and fix things, but i am NOT a fabricator whatsoever. My brain just isn't wired like that.

Supplied Stainless Caps:
View attachment 616681

New Aluminum Caps:
View attachment 616682

Comparison Photos:

View attachment 616684

View attachment 616685

Test Fit (like a glove):

View attachment 616686

Sanded and ready for powdercoat:

View attachment 616683

Do you mind asking him if he'd be willing to do these again? I would like him to take my money! Those look amazing. I assume that this is the same person that make your 45* roof angle as well?
 

RAM5500 CAMPERTHING

OG Portal Member #183
Do you mind asking him if he'd be willing to do these again? I would like him to take my money! Those look amazing. I assume that this is the same person that make your 45* roof angle as well?

Sorry man. I didnt even want to ask him to do these for ME, but i knew he could do it easily. He builds trophy trucks and super slammed at work since all the races just started up again. I dropped these off a couple weeks ago, and he just got around to doing them. Said only took 30 mins, but having a free 30 mins was the delay! Yes, same friend that did my roof 45 angle.

I hateeeeee asking friends for favors, but sometimes ya gotta do what ya gotta do.

Depending where you are located, it shouldn't be that hard to find a fabricator to make some. Just bring a piece of the extrusion with ya so they can match the radius
 

Forum statistics

Threads
188,135
Messages
2,902,614
Members
229,582
Latest member
JSKepler
Top