Comments needed...Self Build Camper

[Rbertalotto]

I realized that I put this post in the wrong area......Maybe I'll get more action over here.......

Hello, new to the site.......

I'm going to build an very light, expedition "shell" for my 3.4 ton 4X4 Dodge Diesel pick-up with 6.5' short bed. This will be a "tailgate open" camper.

Basically just for covered sleeping, storage, and a place for "co-drivers" to sleep on the long haul trips......

I've had two other pick-up truck campers in my lifetime, but they are all too large and heavy for what I need now.

Attached are the drawings for the unit I will be building. Being a well versed boat builder for many years, I'm going to use much of that technology.

The exterior will be 3/8" Epoxy impregnated Wacky Wood with the interior being 1/8" white fypon. All casework will be Mahogany frames with Baltic Birch doors. Two drop down bunks will be hinged to both sides.

Spray in foam will be used in the void between interior and exterior sheathing.

Portable "Cassette" toilet and Propane Catalytic heater will handle the comfort areas. Cooking, cleaning, showers etc will be handled outside.

My biggest challenge will be the two front corners which will require fabricating a double curve. I was thinking about solid block of Styrofoam with fiberglass cover? The side and front curve will be easily accomplished with Wacky Wood.


I've calculated total weight of 700 pounds.

I'm looking for comments, suggestions etc before I start construction.

Thanks

 

[southpier]

is wacky wood suitable in a wet environment without depending on resin coating? if the inside wall of the cavity is 1/8", won't the expansion foam distort it?

 

[Rbertalotto]

With the supports at 12" OC, I should be ok. But I might try an experiment first.

I've used Wacky Wood in marine environments with no issues. It will be sealed inside and out with West System epoxy.

 

[EuroJoe]

looks like a great start

 

[Rbertalotto]

First question would be what the radius of your bends (they look like9-10 inch?) and are you sure 3/8 can do it - I couldn't dig up any data sheets on wackywood. I've use the 3/8" product to wrap 8' columns. It should be fine

Next would be bending ply has all the plys going in one direction (so it bends...) but that leaves it much weaker - no cross grain strength - generally you add glass cloth to give it cross grain strength. I was thinking of adding glass cloth, but the weight gain of adding ribs 12"OC was less than the cloth and extra resin. 3/8" Wacky Wood across 12" is no issue in this use.

Another would be why use weak bending ply for the whole exterior when it's almost all flat - I'd think about scarfing ply & the bending ply.This would be lighter since you don't need as much framing with the stiffer ply. Good point, but I'd rather have as few joints as I can.

Since it's almost all flats why spray foam? you'll have to "screed" off the excess or get bows in your inner panel as southpier pointed out. Flat insulation panels would much easier - use spray just for the odd spots. I'm building it "inside-out". I'll fill the cavities with foam, screed, and then applythe outer skin.

Lighter exterior ply w/glass sheathing would be lighter & more durable (with the pain of finishing the glass...) About the same weight, and much more work and expense.

Personal taste expressed here - Nothing wrong with a plastic interior panel - except it's ugly - why not 1/8 okume? You sound like my wife. She wants interior wood even though I know she'll never step foot into it. Motels are her idea of roughing it

Finally...is this a "sport" build (for fun/personal challenge) or are you trying to save money (this assumes you have time, time & more time...) I ask because there are any number of more direct routes to getting a shell like you sketched out onto your truck & rolling down the road.
But what would be the sport in that! Peter I'm trying to keep the cost down because I'm not sure it will even suit me in the end. I've owned a couple of truck campers that I liked very much, but they were simply too large for the off roading I was doing (Hunting / Fishing). If this doesn't work out, I'll sell it or simply throw it away. I looked at many comercial versions. Anything insullated and a "slide in" cost way too much. And a simple aluminum camper top is too hot/cold and isn't tall enough, and still costs way more than they should. .........And I love to make stuff!

 

[theMec]

My choice would be to have vertical sides instead of angled. Then you can lean your back against the side when you're inside. It makes it feel larger too.

 

[getout]

I wonder this often and because your looking for comments/questions, I'll ask. Why stop at 60" and not just add another foot to the height so you can stand in it? Gas mileage? Weight? You're really only 4' 8"?

Just curious.

 

[Rbertalotto]

My choice would be to have vertical sides instead of angled. Then you can lean your back against the side when you're inside. It makes it feel larger too.

I had a camper top on a vehicle a few years back with vertical sides that stuck out and hit every branch I went near. I though having it follow the contour of the truck's cab would lessen this.......

 

[Rbertalotto]

I wonder this often and because your looking for comments/questions, I'll ask. Why stop at 60" and not just add another foot to the height so you can stand in it? Gas mileage? Weight? You're really only 4' 8"?

At 60" it will give me enough height to put my pants on. I don't plan on spending much time if any inside this camper. Mostly for sleeping and changing cloths. If I'm in there, I'll be reading and laying down.....I'm 6'1" Once it gets more than 5' tall, I think it will look top heavy and disproportionate.

 

[Rbertalotto]

So.... After all this planning and I sourced windows from a place out in Indiana that bought out a bunch of bankrupt motorhome fabricators, and I'm ready to build.........

I find this down the street from me for $1500....

...I really don't want a true pickup truck camper, but this is an amazing deal. It's like new with just the right amount of accouterments. Pretty simple and very light weight.

I'll need to sleep on this and see where I land.........