Building a roof????

Funrover

Expedition Leader
So I completely rebuilt my pop up a few years ago..... But the roof need to be redone entirely..... I want to keep it light as possible.... However I do take this camper on mild to moderate 4x4 trails..... I also figure that in the future it will hold 2 kayaks or something of similar weight while in transport! What have others done? I am up for any ideas.. I entertained the thought of 4 yakima crossbars and sheet metal at one point.... but am not toally crazy about that idea yet!

Thanks!
 

Funrover

Expedition Leader
1971 Cox Conestoga

IMG_7011.jpg
 

Curtis in Texas

Adventurer
I had a Jayco some years ago and used 4 cross bars from a yackama rack to carry my Jocassee Kayack and two mountain bikes on top.
Seeing your pictures sure brought back the memories.
I used to drag mine everywhere behind my Rodeo. Too bad all my pictures are in my crashed hard drive.

I used four cross bars to spread the load evenly across the roof, as you've probably thought of.
The roof carried the weight well as it was all carried on the edge of the frame.
And of course the frame being wood was a concern. After a few years it did have a problem with it sagging because I put a 1500 BTU AC unit up there. It was only rated for a 1350 btu unit. I liked to camp in the desert. Nothing like being able to camp in Death Valley and be able to relax in a cold camper after a long hard mountain bike ride and a shower.
My Pop Up was a hit with the lady cyclest!:wings:
Always a crowd around it after a hot ride. I ended up adding an exra propane and water tank to have enough water for more showers.

Been thinking of getting another one, only used this time ,and building a stronger frame to mount under the facory frame with bigger wheels and axles.

For the money, a Pop Up Camper is a nice way to go.

If you stripped the wood frame off and copied it in steel tubing you could have more strength, but I would wonder if the weight might be too much. Maybe not if the tubing was thin wall.

Curtis
 

oldcj5guy

Adventurer
I have redone a few roofs for people using thinwall aluminum tubing tig welded and then covered with either plastic or fiberglass. With the tubing setup if the roof is high enough you can add in a layer of styro insulation between the tubing and ceiling.
 

Funrover

Expedition Leader
oldcj5guy said:
I have redone a few roofs for people using thinwall aluminum tubing tig welded and then covered with either plastic or fiberglass. With the tubing setup if the roof is high enough you can add in a layer of styro insulation between the tubing and ceiling.


Would you be willing to help me? or show pics? I don't have a lot of $$$ being in college so that is also important!!! But I am really interested in what you are saying!! I also don't have a tig welder.... only mig/arc! This sounds great!! How much does this cost? have any pics?
 

oldcj5guy

Adventurer
Never bothered to take pictures. I was flat rate at an RV dealership at the time and time was money. I don't have a tig anymore, but it would be possible to mig together thinwall steel and still keep the weight down. I am hoping to either get a tig or a bigger mig and a spool gun come tax time.
Full time college student here too again with my wife going full time also.
Which school are you in?
 

Funrover

Expedition Leader
I am at UCCS (University of Colorado Colorado Springs) Mechanical Engineering!

You are as busy as me!!! I have never built a roof on a camper before so any help,tips, ideas is great!

Thanks a million!
 

njtaco

Explorer
x2 on the styrofoam...studying M.E. you know about the strength available in lamination. "Most" pop-up roofs have no metal framing at all, just wood/foam/aluminum skin laminate, with wood "trusses" running side to side to support the air conditioner. If they were not ac prepped with internal strengthening, steel or aluminum supports are added to the inside ceiling and tied into the "sides" of the roof structure.

Be careful about too much weight...the lift system is only so strong.
 

oldcj5guy

Adventurer
The apache guys are real innovative. I am amazed at some of the ideas they come up with over there. A lot of them use small window ac's mounted inside a cabinet with the rear portion sealed to the exterior but inside the sideline of the coach.

The only reason I am sold on the apache is because it is a hardside and it is allowed into campgrounds in bear country.
 

Funrover

Expedition Leader
oldcj5guy said:
The apache guys are real innovative. I am amazed at some of the ideas they come up with over there. A lot of them use small window ac's mounted inside a cabinet with the rear portion sealed to the exterior but inside the sideline of the coach.

The only reason I am sold on the apache is because it is a hardside and it is allowed into campgrounds in bear country.


My parents had an apache when I was a kid.. That was a great camper...Wish we still had it!
 

Funrover

Expedition Leader
oldcj5guy said:
Say hello to my PVC snorkle...LOL..... but it works....LOL

Does this belong to anyone here?



ROFLMAO!!!! I see you visit co4x4.org..LOL..... Yeah what can I see it was an easy yet functionable mod!!!
 

Funrover

Expedition Leader
LOL I have been caught!!! ********!!!!

I actually enjoy it here more..... A lot more helpful , I can find more informationa and not all the politics and such!
 

Forum statistics

Threads
189,100
Messages
2,912,947
Members
231,750
Latest member
travelall74
Top