DIY Composite Flatbed Camper Build

[Terra Ops]

Purchased four Destaco 341 R latches, holding capacity is 2000 lbs each. U bolts were not long enough so I had to special order.
This company was very helpful http://jericoinc.com/

 

[pennersm]

Grey tank assembled and installed.

I think that is a great idea, creative thinking!

 

[Terra Ops]

I think that is a great idea, creative thinking!

Thanks! Here are a few more pics after install.
Pipe is in an L shape going from left to right with the drain in the back.
The flex hose allows for flow in the 180 turn from camper to tank. It can also be tucked into the flatbed
when camper is off. Quick disconnect should make hook up easy.
The tank is not pretty but doesn't need to be since you aint going to see it

 

[Terra Ops]

Landing gear installed on steps. Cut, drilled, screwed and sika 252.

 

[Terra Ops]

U bolts for the latches arrived and installed, touch up paint complete, and the best part of the day was the test drive.
Handling and ride exceeded my expectations due to its light weight. I usually notice an immediate drop in mpg with our other camper,
however mpg hovered around 19. "Camper was dry" I would think with this type of construction, a camper could be built for virtually any vehicle.
Remaining to do list; awning, graphics, make an insulated cab to camper boot, and figure out the air conditioning.

 

[Mundo4x4Casa]

Terra,
I like your plan and execution. The ladder looks like a disassembled Little Giant 5-step with the leveler feet attached, no? Where do you store the ladder when not in use? I may have missed this as I only scanned your build process. About the air conditioning, I would caution putting anything on the roof, especially if you're planning on lots of off-camber, off-road. Although I've traveled a lightweight, full featured Lance Camper path, I'm happy with the result. We use a cut down 4-step Little Giant that we hang on the rear ladder for transit.


and maybe a short vid on the sand hill at Arroyo Secco del Diablo: tire pressure: 20 pounds. start in 4th gear low range, downshifting to 2nd gear low range for the deep moguls: click to open:
https://www.dropbox.com/s/bfj5y93wsd7vfkw/jefe does sand hill at dry wash of the devil Anza.m4v?dl=0
jefe

 

[Terra Ops]

Terra,
I like your plan and execution. The ladder looks like a disassembled Little Giant 5-step with the leveler feet attached, no? Where do you store the ladder when not in use? I may have missed this as I only scanned your build process.

Thanks and yes, same type of ladder. See previous page #184. I plan to make a rack to hang horizontally across the back.
What type of air conditioner do you have? I'm looking for a 12 volt for either roof or back wall.
Liked your video, looks like a stout rig!

 

[CoyoteThistle]

Man, looking great! Congratulations on the test drive - that's a big moment!

What's your approach to getting graphics done? I've been thinking large vinyl stickers from a local print shop but have no clue if that is a good approach or not.

 

[Terra Ops]

Thanks! I appreciate that, only a fellow builder could understand the first test drive

I've used vinyl in the past and have been happy with the results. They can basically print any logo/design inexpensively. I may check into a wrap just to see
what's available and cost.
Here is a vinyl compass on our old Tiger.

 

[Terra Ops]

Steps mounted

 

[Terra Ops]

Awning install. Went with a dometic A&E 9500 Case awning.
Self supporting and a decent price.
This is a fairly easy install. Once again the aluminum L channel have proven to be a strong
attachment point using rivets, stainless lag bolts, and SIKA 252 to secure the mounting plate.
Give it a few days to cure, then I'll insert the awning.

 

[Terra Ops]

Awning is up and insulated boot to cab is made. Not sure how well this will work yet, hope to get it loaded up again and do some more testing next week.
I may have found the perfect AC. After the Chinese/Alibaba "still ongoing" experience, I thought I found a 12 volt roof unit. "Thought" is the key word here.
It's so frustrating when communication just stops for no apparent reason. Once again I think it has to do with the small sale or little guy. Just not worth the effort.
But, this may hopefully be a good thing after all. After searching and looking at various cooling methods, I came across a brand new product. Its a portable 12volt
1100 btu AC. Only 14 lbs and uses very little amps. 1100 btu does not sound like much, but I suspect for my camper it will be sufficient. I've been impressed with how well
it holds current temperature. Its like a big cooler. This portable AC is suppose to cool a 50 square foot room down to 44 Fahrenheit. I'm not going to say much more about it until
it arrives and more testing can be done, but my hopes are high

 

[Terra Ops]

Went with vinyl for the graphics- $60.00.
The foam cushion definitely created a tighter seal between cab and camper.
Wind noise level was less at highway speed. Probably due to the foam boot and wedge
shape of the camper.
As for Air conditioning, I feel like I'm flip flopping all over the place trying to find efficiency, light weight, reasonable cost, and reliability.
I decided to cancel my order for the portable 1100 btu unit. While it looked promising in a You Tube video, comments, poor customer
service and further research scared me off. Here it is for anyone interested;

 

[Terra Ops]

Preliminary observations with the REDARC and drop in Stark batteries using only solar "400watts";
When I kill the batteries to the camper and just allow solar charging, I've seen a max charge of 14.1.
As soon as I turn the switch back on with no inverter activated just 12v units (not on, just power to) such as water pump, TV, fridge, heater, and light bars,
the charge gradually drops to 13.6 and seems to stay there all day. I have yet to do any traveling for real world testing.
I did turn the fridge on after sun down to see what the draw down looks like.
Overnight voltage dropped from 13.6 to 13.2 running the fan and frig. Boiled some water on the induction and microwave, made a cup of coffee with the Keurig and it dropped to 13.1.
Morning was overcast with no direct sun but there was some charging. About 2 hours of direct sunlight and voltage came up to 13.5 with frig compressor running and stayed there. Turned the Frig
off and voltage almost immediately goes to 13.6. Kill the power to the camper and batteries once again rise to 14.1 in about an hour and a half with full sunlight.
This was solar only with no drive time/ alternator use. So far I'm impressed with the power output of the lithium. I'll report more once we get a few overnighters in. Still waiting on the AC which will be interesting to see power consumption. I expect it to be minimal. We have had some hot and humid days. Just driving around with a clip on fan to move AC from cab to camper cools it enough to where I can see it not taking much more to maintain desired temp. The panels do an excellent job holding temp.

 

[Terra Ops]

I've been having a problem with the water pump pulsating. It is a Shurflo by-pass pump that does not need an accumulator.
I checked all the lines for tight fittings and made sure there was no air too. None of this helped.
In the operation manual it talks about a by-pass adjustment that should only be performed by a professional technician with proper gauges
and equipment. Well, it just doesn't seem that complicated so I adjusted until the pulsating stopped. Problem solved
Another glitch I'm having is the drainage from camper to gray tank. Seems it works best if the drain line does not get smaller. Guess I'll be replacing
it when we unload the camper