I have a plan to turn my 7 x 4 box trailer into a camper with a full pop-up roof, sleeping platform for the adults and room underneath for the kids. I’ve been inspired by lots of truck campers designs built with 8020. I have no welding skills and no workshop but I can sew and use basic tools. I have never done anything like this before. I have been reading lots of forum threads/ builds.
I plan to use the trailer for weekends/holiday camping with my kids, mostly accessed by blacktop roads with some dirt/sand sections. No “real” off-roading. The trailer was built as a semi off-road trailer out of steel, all terrain 16” tires, eye to eye leaf springs, offroad hitch. The side walls of the box trailer are deep (500mm). We live in Australia, it doesn’t get below 10 degrees Celsius when/where we camp. The camper will also accommodate 4 push bikes when travelling.
Here is my 7x4
I'm trying to achieve something like this for on the trailer.
My design
Topper frame :
Dimensions: 600mm (h); top section length 2500mm (overhang ~360mm), width 1410mm; bottom section 2140mm(l), 1360mm (w).
Materials: metric 3060, 3030 t slot aluminium extrusion, 3mm aluminium composite cladding. Tapped and joined with bolts, gussets/plates as needed, and plenty of Loctite.
Roof frame:
Dimension: 2500mm (l)x 1410mm (w) x 60mm (h)
Materials: metric 2060, 2040 t slot aluminium extrusion, 3mm aluminium composite cladding. Tapped and joined with bolts, gussets/plates as needed, and plenty of Loctite.
*I’ve tried to overlap the topper frame to spread that load over the trailer's 50x50mm steel corner uprights.
*The topper frame is a little wider than the trailer box so that the bed platform can be wider.
*The total height of the camper will be close to the height of the tow vehicle, maybe an inch higher (I need to be able to fit the bikes inside the trailer).
*I might add a half size panel door on each side for airflow. I thought about RV windows but they will add more weight. Plus not sure I can accurately cut the holes in the panel.
*I’ll try to make sure all access holes for bolts in the extrusion are accessible
*Not worried about thermal bridging.
*Will have a lift up rear door that meets the tailgate.
*I haven’t worked out exactly how I will attach the topper to the trailer. Some plates and bolts on the outside plus rachet straps between frame and trailer tie down points on the inside, I could also use the exterior tie down rail that runs the outside perimeter of the box,
*The sleeping platform will be modular, yet to work this out.
I want to make sure this thing is safe (we will be driving to the road conditions and are not in a hurry) and won’t fall apart with the first bump in the road. Can anyone see any serious flaws with the frames? Any advice?
Also does mounting the aluminium composite panels in the t slots with the weather sealing significantly impact frame rigidity compared with mounting the panels to the outside of the frame??
Thank you!!!!
I plan to use the trailer for weekends/holiday camping with my kids, mostly accessed by blacktop roads with some dirt/sand sections. No “real” off-roading. The trailer was built as a semi off-road trailer out of steel, all terrain 16” tires, eye to eye leaf springs, offroad hitch. The side walls of the box trailer are deep (500mm). We live in Australia, it doesn’t get below 10 degrees Celsius when/where we camp. The camper will also accommodate 4 push bikes when travelling.
Here is my 7x4
I'm trying to achieve something like this for on the trailer.
My design
Topper frame :
Dimensions: 600mm (h); top section length 2500mm (overhang ~360mm), width 1410mm; bottom section 2140mm(l), 1360mm (w).
Materials: metric 3060, 3030 t slot aluminium extrusion, 3mm aluminium composite cladding. Tapped and joined with bolts, gussets/plates as needed, and plenty of Loctite.
Roof frame:
Dimension: 2500mm (l)x 1410mm (w) x 60mm (h)
Materials: metric 2060, 2040 t slot aluminium extrusion, 3mm aluminium composite cladding. Tapped and joined with bolts, gussets/plates as needed, and plenty of Loctite.
*I’ve tried to overlap the topper frame to spread that load over the trailer's 50x50mm steel corner uprights.
*The topper frame is a little wider than the trailer box so that the bed platform can be wider.
*The total height of the camper will be close to the height of the tow vehicle, maybe an inch higher (I need to be able to fit the bikes inside the trailer).
*I might add a half size panel door on each side for airflow. I thought about RV windows but they will add more weight. Plus not sure I can accurately cut the holes in the panel.
*I’ll try to make sure all access holes for bolts in the extrusion are accessible
*Not worried about thermal bridging.
*Will have a lift up rear door that meets the tailgate.
*I haven’t worked out exactly how I will attach the topper to the trailer. Some plates and bolts on the outside plus rachet straps between frame and trailer tie down points on the inside, I could also use the exterior tie down rail that runs the outside perimeter of the box,
*The sleeping platform will be modular, yet to work this out.
I want to make sure this thing is safe (we will be driving to the road conditions and are not in a hurry) and won’t fall apart with the first bump in the road. Can anyone see any serious flaws with the frames? Any advice?
Also does mounting the aluminium composite panels in the t slots with the weather sealing significantly impact frame rigidity compared with mounting the panels to the outside of the frame??
Thank you!!!!