Flatbed Hard Side Pop Up Camber Build

[Crosley623]

I’m working on design for a new camper build.

I’ve had a few over the years, including a few vans and pull behind campers. I want to try the truck camper route but want to build from scratch.

Plans:
- 2500 truck converted to flat bed. Thinking of building my own flatbed with the kit from DDH fab.
- was originally wanting to do a hard side but due to height I can’t fit it in my garage so that idea has been scrapped. Now going pop top. Not sure I want to learn how to sew so thinking some sort of hard side pop top.
- I’m going to fully weld aluminum frame from 1” tubing. I looked into the composite panels but it seems like sourcing them is tough.
- ACM (MaxMetal) aluminum composite panels on the outside. 3m taped. I was thinking aluminum angle riveted along the corners for protection and for a weathertight seal.
- inside spray foamed and then covered with wood paneling.

Fairly early stages but that’s my initial plan. Anyone have any advice one way or the other on this construction plan??

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[jmnielsen]

I have no clue what your plans for use are, but if it were me I would get rid of a few of the crossmembers on the roof. Will cut weight and it would be unnecessarily strong. I would also add something more than a 1" square tube across the top of the camper, something more like a 1x3 or 1x4 depending on what sort of weight you intend to put in the cabover.

 

[1000arms]

Alaskan Camper has been making hard-side pop-up campers for many years. You might want to look at them for ideas.

You might be able to build your hard-side camper AND fit it in your garage. 😀

https://www.alaskancampers.com/

 

[Crosley623]

I have no clue what your plans for use are, but if it were me I would get rid of a few of the crossmembers on the roof. Will cut weight and it would be unnecessarily strong. I would also add something more than a 1" square tube across the top of the camper, something more like a 1x3 or 1x4 depending on what sort of weight you intend to put in the cabover.

Good point on the roof.

For the sides I couldn’t find anything similar stock to what FWC uses. I thought the truss design may be strong enough. I’ll have to do some more research in that area.


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[dstefan]

Check out this thread. He did a fabulous job with an innovative approach.

I have finally started my new build!

This truck will be THE BEST... at nothing!

My build platform is a 1995 Toyota T100, extended cab, 4x4, 3.4L V6, 5 speed manual trans. My wife, dog, and I have already lived out of this truck with a very basic DIY camper while traveling through Mexico and Central America for 1.5 years.
View attachment 661716
We learned a lot during that trip and have decided that we want to improve our foul weather living conditions. The goals for the new build are a fixed queen size bed, indoor composting toilet, indoor kitchen, insulation, maintain enough storage for all our toys, and maintain the vehicle's on and off-road driving performance relative to our previous camper set up.
The plan is to build a hard-sided popup camper out of DIY composite panels.
View attachment 661720View attachment 661722View attachment 661723

The panels will be constructed of 5mm plywood, .75" XPS foam board, 1x2 dimensional lumber, 6oz fiberglass, and epoxy resin. All wood will be soaked in epoxy and all exposed surfaces will be laminated with fiberglass inside and out and all joints will be reinforced with additional fiberglass tape. The camper will be mounted on the truck via a steel subframe. The subframe will be constructed of 1x2 rectangular tubing and bolt to the 6 stock bed mount locations on the truck frame.
View attachment 661724
This little video may better illustrate the idea:


I've removed the old truck bed and rear bumper and cleaned up the truck frame to start work on the sub frame.
View attachment 661745
I'm new to welding, but the mig and self dimming helmet have me feeling way more comfortable than when I briefly tried stick welding 15 years ago. I'm excited to get started!


People either love the T100 or think I'm an idiot for driving one. So, to help folks on the internet criticize me more accurately I'm going to share some relevant info here:

Price= $2,500 usd	length = 209.1"	width = 75.2"	height = 70.1"
max payload = 1960 lbs	curb weight = 4040 lbs	turning circle = 43.3 feet	Torque = 220 lbs-ft
Estimated fuel efficiency = 15/18 mpg	Ave. fuel efficiency with old camper = 15.5mpg	fuel capacity = 24 gal	Horse power = 190