DIY/Homebuilt Camper - Flatbed Tacoma Doublecab

[ekibike]

Hi ExPo! My wife, Robin, and I, Zach, have been reading the forum for a while and gotten a lot of great info and inspiration from it. Thanks!

Now it's our turn - we're building a camper for our 2014 Tacoma Doublecab and will be documenting the build here. This first post is a bit more about us and the process that led to making the decision to build instead of buy.

We'll be making subsequent posts to keep you all up to date on the build progress. Or, you can follow along on our blog (http://selwyndoeslunch.wordpress.com) and instagram (@selwyndoeslunch). The posts here will mirror the blog. We've also for a build thread on Wander the West: http://www.wanderthewest.com/forum/topic/13112-diyhomebuilt-camper-flatbed-tacoma-doublecab/

We've always loved to travel and camp together and have had many vehicles that have taken us on these adventures. Over the past few years, it became clear we needed another #adventuremobile. One of our big regrets is that we did not bring Faith home with us when we returned from our adventure in New Zealand. Faith was our kitted-out 4x4 Toyota LiteAce van. She had a bed in the back and all of the necessary camping supplies. Last we heard she had been de-registered. We miss her dearly.



So, thanks to Faith's inspiration and the desire to travel, a camper seemed like a fun idea. In a camper, we could cook and sleep indoors and off the ground. And, thanks to the truck, we could take our new home anywhere we wanted to go. Winning!

After deciding we needed (it's a need, right?) a truck camper, we began looking at our options. Something simple, lightweight, and capable.

We started with the idea of installing a Flippac and building out a custom interior in the bed of our truck. We were for sure going to get the Flippac.

Then, we decided that although the Flippac was great, it wasn't for us (for lots of reasons) and it was either an All Terrain Camper or Four Wheel Camper. In the end, we were for sure going to get an All Terrain Camper (ATC).

After making our final decision, and knowing we were getting an ATC, we ordered a flatbed from Ute Bed to replace the stock bed. Once the bed was installed, the plan was to order a custom flatbed version of ATC's shell camper and build out the interior ourselves.

But, after we ordered the flat bed we were once again overcome with indecision and options.

Just what we needed, more options for our teeny tiny camper/tent/yurt/whatever. We flip flopped so regularly on what we wanted that we would get agitated anytime the subject arose. Not to mention the logistics (and costs) associated with actually getting the ATC camper from halfway across the country (either we pay tons to ship it, or we drive out to get it and pay tons in travel and time off costs - lose/lose).

Finally, finally. We decided to strike out on our own and build one ourselves. What's the worst that could happen? Right? Here's what we're shooting for:

 

[ekibike]

Next Phase of the Build - We get a floor!

The first thing we decided to build was the floor. After visiting literally every hardware store in a 10 mile radius, lumber and supplies were purchased and the first cuts were made for what will become the floor of our tiny truck camper. We used analog and digital plans.



Saturday 5/14:
The plan was to sandwich 1x3s between 1/2″ marine grade plywood* to create the floor. It would require a glued seam to make up the full 6′ x 6′ dimensions. The seams would be perpendicular to each other to increase stability. So, we cut one sheet of ply straight down the middle and lopped off the ends. The build had officially begun.

The original plan was to rip 1×6 treated wood into 1×3 pieces and use that as the framing. Treated wood sounded like a good thing. Why wouldn’t we want treated wood. Our little camper was going to be outside and exposed to the elements. Of course we wanted treated wood. But once we got our hands on it we realized we had made an error. It was wet. Real wet. A quick internet search set us straight*. But now the lumber store was closed because it was Saturday after 1pm. Back to the internet. Lowe’s had some cheap furring that was twice as expensive as Kemah Hardware, but kiln dried unlike Home Depot, and available from 6am to 10pm.

Sunday 5/15:
Now that we had appropriate lumber in hand, we got to work. After we attached longer framing pieces to the base floor plywood pieces we glued and pressed the seam and attached cross framing. Because we don’t have enormous clamps, to set the glued seam we sandwiched the two pieces of ply between a piece of drilled down wood and a clamped scrap 2×4. We used the truck chains to hold the middle of the seam flat.



Once the outside framing was attached we created a 3×3 grid of framing. All the framing was glued with construction adhesive, clamped, and screwed with decking screws.



With the framing complete we hurried to check the fit before heading out to a friend’s graduation celebration.



Friday 5/20:
6″ square blocks were cut out of scrap 3/4″ plywood hanging around the garage to use as bolting blocks in the corners of the camper. 3/4″ solid insulation was cut to fit inside the 3×3 grid minus the bolting blocks.



Saturday 5/21:
The bolting blocks were glued and screwed into place and the insulation was glued into the grid. We found here that the 3/4″ solid insulation was slightly taller than our 1x3s, which are supposed to measure 3/4″ on the “1” side. *Turns out that neither of them were actually 3/4″. Figures. That riddle could wait until the next day – we had beer to drink at Texas Beer Refinery’s 2nd anniversary shindig.



Sunday 5/22:
We did our best to squish the insulation down but in the end just glued and screwed down the top pieces of ply and it seemed work out just fine. The location of the bolting blocks and the framing were marked on the outside and the top and bottom labeled. Besides from one side being just so slightly overhanging, the floor was DONE!



Supplies:
1/2″ Marine Ply (4′ x 8′)
1″ x 6″ x 8′ Treated Lumber
3/4″ Polyiso R-Matte Insulation
1 1/4″ Deckmate Deck Screws
Loctite Heavy Duty Construction Adhesive
1″ x 3″ x 8′ Furring
Scrap 3/4″ Plywood

*Lessons Learned:
1) Marine grade ply only refers to the glue used to hold it together, it is not sealed in anyway. It will de-laminate just like any other plywood
2) Treated wood is not a good idea
3) 3/4″ (or any other measurements) doesn’t necessarily mean 3/4″

 

[ekibike]

Front and Back Walls

We picked windows!



Post window decision, we had some celebratory beers. We earned it, after all. We’re not very good at decisions some times. We were asked by the cashier if we were building a tiny house. We laughed, looked at each other and then said “Yes! sort of.”

During the week we adjusted to the sketchup plans for the back and front walls to include proper window openings and framing.

Saturday 5/28:
The walls will be framed by 1x2s and 1x3s sandwiched between two sheets of 1/4″ marine grade plywood. To start we plan to build the walls with the interior ply only. Once they are all done we will build the thing and then add the exterior plywood.

We started by cutting the plywood and framing pieces for the back wall. It’s taller than 4 feet so there’s a seam that runs horizontally on the interior braced by 1×3 framing. Because we don’t have enormous clamps, to set the glued seam we sandwiched the two pieces of ply between two scrap pieces of wood and then clamped what we could. A heavy tool box on top of a flat piece of wood helped keep the middle flat.



We were most of the way done when we realized that one of the 1×2 pieces we bought was rather twisted. Begrudgingly, we made a late night run to Lowe’s to pick up a replacement and more framing for the front wall.



Sunday 5/29:
We finished framing the back wall!



We then moved on to the front wall. Same routine. Cut ply and framing, attach with glue and screws.



After a dip in the pool, we moved the floor and both completed walls to the dining room for safe keeping. This process was the most painful of the day.

Supplies:
(2) 1/4″ Marine Plywood (Kemah Hardware)
1″ x 2″ x 8′ Furring (Lowe’s)
1″ x 3″ x 8′ Furring (Lowe’s)
Liquid Nails – Heavy Duty (Lowe’s)
1″ Premium Decking Screws (Ace Hardware)
14″ x 21″ Aluminum Mobile Home Windows (Lowe’s $27.00 each)

 

[ekibike]

Side Walls

This is how we built our side walls. We smile, we cry, we build walls. Enjoy!

- Total Days: Seven
- Total Time: 26 hours, 12 minutes, 20 seconds




Saturday 6/11:
We didn’t have a lot of time this weekend but we managed to cut the plywood needed to make up the interior wall on the driver’s side. Today’s challenge was angled cuts. Geometry, oh my!

For the front piece of plywood, we used the oscillating saw to finish off the corner that meets the front wall and the cab over section.





Saturday 6/18:
Today we used the wall panels we cut last weekend to cut the passenger side walls. After getting the wall panels cut, we took a pool break. Then, we began working on cutting framing pieces. No gluing or screwing today, but the components are coming together. Oh, and it rained SUPER HARD while we cut framing. We were serenaded by thunder and Bruno Mars.





Saturday 6/18:
Six and a half hours of work resulted in a near-finished driver side wall. Today we figure out how to cut angles, and nailed each the first time! One more wall and we’ll be ready to start raising the barn.



Saturday 7/11:
Lots of gluing and screwing later we finished the driver side wall we started a few weeks ago. Nosnafus or challenges to speak of. Not so fast, hot-shots! Turns out, we built things inside-out. Our entire design hinges on having the entry door on the passenger side so that we can access the camper while on the side of the road without playing in traffic. Safety first, kids. So, after a fair amount of swearing, and some time justifying how having a door on the driver’s side wouldn’t actually be that bad (even though, it would), we got to thinking. Luckily, we were able to pull off some freshly laid framing and convert the inside-out driver side wall, to the right-side-out passenger side wall we needed it to be. Presto-change-o, we’ve got a wall ready to get a door. Wrong! A few bits of framing had to come back out…





Sunday 7/12:
We woke up this morning jazzed about having fixed what seemed like a deal breaker on Saturday. Challenges? We laugh at challenges.

Today we built the driver side wall (correctly, and in one go) and finished with 4 small framing pieces left to attach before being completely done with wall framing/prep. Great end to a big work weekend!

Saturday and Sunday 7/16-7/17:
As we get ready to put things together, it has become very obvious that we need to be able to move the camper around in the garage as we work, and that it has to sit pretty close to the ground so we can get it out when it’s time to go on the truck. After poking around online during the week and thinking/talking through some ideas, we decided that we could build a rough dolly for the camper using 2 x 6s (3) and 2 x 4s (2) with six large casters on the bottom. So, we started our day by cruising the hardware stores shopping for the components.

On Sunday, we finished the attaching the 4 framing pieces from last week and then cleaned up the garage in anticipation of putting the pieces together in the coming weekends. Another great and productive weekend in the bag.





Materials:
(4) 1/4″ Marine ply
(4) 1″ x 3″ x 8′
(so many) 1″ x 2″ x 8′
Liquid Nails Heavy Duty (lots)

 

[IdaSHO]

Looks like you are well on your way, and having fun doing it!

I may have missed it, but what are your reasoning for the shape of the camper?

For such a small space, the reduced ceiling height in the front and the back seems like a bit of a waste of what space you do have.


Looks good though, keep it up! :ylsmoke:

 

[ekibike]

Sorry for such a delayed response. I never got a notification of your comment and, as you may have noticed, I've dropped the ball on keeping up with this thread.

Anyway, the shape is meant to give us a bit of a shelf up front (the cabover) without stretching too far forward because we weren't sure we could build it strong if it was too long. The peak is high enough to let us stand without going much higher and we went for a sloped roof to make sure no water could sit on top - we live in Houston and, as you've seen recently, it can really rain here. Basically, we wanted an indoor space to sit/sleep and do some very light cooking. Nothing more.

Since these posts, we've completed everything but the furniture and connection to power. As of now though, it's not mounted on the truck because we wanted to test it for a while first so it's mounted to a little trailer.