Custom build pop-up camper

[andy.and.beyond]

Lost a bit of momentum when it took a week to get the roof so I quit rushing to finish. I decided to use some EPDM weather stripping and bolt the roof rather than glue or tape it. Also welded up some supports for the middle of the roof. I'll be waiting to fully assembly the roof until I get a fan. I had to use the frame to pick up the roof so now I'm moving few steps backwards and took everything off the frame to add weather stripping and start the final assembly. Also decided just to use Plexiglas for the front(lid) and back(against the truck) that way I don't have to add windows for visibility.

 

[4x4JeepCamper]

Nice welding on the aluminum.

 

[andy.and.beyond]

Nice welding on the aluminum.

Thanks! the first couple didn't look as good. Takes me awhile to remember what I'm doing since I don't weld that often.

 

[andy.and.beyond]

Here is another update

I machined some new gas shock mounts, I wasn't really happy with the old ones and needed to recess the head for the spring. I made a quick mounting plate for the movable bed portion and clamped some scrap on to give it a feel.trying to see how much bed I need without my feet being squeezed in at the bottom. I'm not 100% happy with the height I have it opening to at the moment, trying to weigh whether opening it up more will really give me anymore foot space. I also I have some stainless ACE hinges on this and they have way too much slop, I'll have to build something myself i suppose since I really want it to mount on both slots. I got all 65 snaps installed on the canvas, I might have to rework the corners a tad but it looks like it fits good. I just need to decide on the height so I can trim the fabric and make some plates to clamp the fabric on the interior slots.

edit: also note I got some side panels mounted. I had some steel ones cut to go on but I got tired of fussing with paint. So i went and got some aluminum cut and figured i'd leave it raw like the roof.

 

[otis24]

Here is another update

I machined some new gas shock mounts, I wasn't really happy with the old ones and needed to recess the head for the spring. I made a quick mounting plate for the movable bed portion and clamped some scrap on to give it a feel.trying to see how much bed I need without my feet being squeezed in at the bottom. I'm not 100% happy with the height I have it opening to at the moment, trying to weigh whether opening it up more will really give me anymore foot space. I also I have some stainless ACE hinges on this and they have way too much slop, I'll have to build something myself i suppose since I really want it to mount on both slots. I got all 65 snaps installed on the canvas, I might have to rework the corners a tad but it looks like it fits good. I just need to decide on the height so I can trim the fabric and make some plates to clamp the fabric on the interior slots.

edit: also note I got some side panels mounted. I had some steel ones cut to go on but I got tired of fussing with paint. So i went and got some aluminum cut and figured i'd leave it raw like the roof.

For the hinges have you looked at hinges for boats? They seem really nicely made, however pricey. But you get what you pay for.

 

[Bob joe]

Just wondering how you at ached the 80/20 at the corners? Did you weld it or make brackets to join it at the 90deg.

 

[andy.and.beyond]

Just wondering how you at ached the 80/20 at the corners? Did you weld it or make brackets to join it at the 90deg.

I fastened it a few different ways. The top is held together with these inside corner bracket(1st pic, from 80/20), an end plate (2nd pic but not installed yet), and the roof will hold it some as well. The bottom is 2 different ways. The end mounted on the frame is just bolted to the frame with the end plates(2nd pic), The forward end that over hangs the cab has these flush mount fasteners(1st pic, from 80/20), an end plate(2nd pic), and a corner mounting plate on the bottom (3rd pic, from 80/20). if someone wanted to build their own they could get by with just ordering items from 80/20. I didn't want to weld the corners since the 80/20 comes with a clear anodize, with the T slots it'd be a PITA, and its an odd alloy that I didn't look into how well it could be welded.

 

[plh]

Great idea. I was thinking 80/20 as well, but man that stuff is expensive.

 

[andy.and.beyond]

Great idea. I was thinking 80/20 as well, but man that stuff is expensive.

Actually its no more expensive per a lb than normal aluminum extrusion, at least for what I'm paying. It just seems more expensive since to get something with the same moment of inertia you need a heavier 80/20 section than with tube. An example. i used the medium weight 3" x 1.5" extrusion. for the same weight I coulda used 3"x 1.5"x 3/16" wall rectangle tube and ended up with something stronger (if i remember correctly).

 

[plh]

Actually its no more expensive per a lb than normal aluminum extrusion, at least for what I'm paying. It just seems more expensive since to get something with the same moment of inertia you need a heavier 80/20 section than with tube. An example. i used the medium weight 3" x 1.5" extrusion. for the same weight I coulda used 3"x 1.5"x 3/16" wall rectangle tube and ended up with something stronger (if i remember correctly).

Per lb probably, but cost per foot of "tube" is way more. I wouldn't really care to cost something like this by the lb.

Internet pricing example: 80/20 3" x 1.5" x 8' - $85 per stick. 6061 rectangular tube 0.125 wall 3" x 1.5" x 8' - $42 per stick ( I can buy for less I think at a local metal warehouse)

 

[andy.and.beyond]

Per lb probably, but cost per foot of "tube" is way more. I wouldn't really care to cost something like this by the lb.

I guess I'm just use to always looking at pricing everything by the lb to estimate costs. It is more expensive but you're buying some functionality with the slots and that just comes at a cost.

 

[andy.and.beyond]

Has anyone had luck finding a source for long gas springs? After adding my roof it just falls down with my 2 50# springs I have now. I can just order 100# springs of the same size from McMaster Carr but i'd be happier if I managed to find some longer ones.

Current spring dims
Extended length - 35.43"
Compressed length - 19.29"
Travel - 16.14"

 

[andy.and.beyond]

Per lb probably, but cost per foot of "tube" is way more. I wouldn't really care to cost something like this by the lb.

Internet pricing example: 80/20 3" x 1.5" x 8' - $85 per stick. 6061 rectangular tube 0.125 wall 3" x 1.5" x 8' - $42 per stick ( I can buy for less I think at a local metal warehouse)

Guess since I recently moved to a new state I haven't found someone to give me a decent price on metal. I'm paying around $5 lb for aluminum so the gap isn't as big for me. That stick in 6061 would cost me ~$60, ~$52 for the metal and a cut charge of $10 (if you wanna price out an 8' length).

 

[plh]

Has anyone had luck finding a source for long gas springs? After adding my roof it just falls down with my 2 50# springs I have now. I can just order 100# springs of the same size from McMaster Carr but i'd be happier if I managed to find some longer ones.

Current spring dims
Extended length - 35.43"
Compressed length - 19.29"
Travel - 16.14"

This is looking great!

For that roof panel, what size sheet, material type and where did you sources it?

 

[andy.and.beyond]

This is looking great!

For that roof panel, what size sheet, material type and where did you sources it?

I used 5052 .060" aluminum, my size was 52.5 x 107.5", and I got it from the metal supplier in town (IMS). I really wanted to do .030" but due to the size it had to come from a 5' x 10' sheet and I had to jump to .060". I was hoping to find some kind of composite like the GFC but i kinda gave up quick. The width and the length kinda made it tough to source something as a single piece. I also had to add some supports for the roof.