Flip-pac camper build

[Bella PSD]

Now it gets a little more fun, and challenging. It’s time to plan out the rear door. Half the reason I started this project. I wanted a door that would give access to the interior, open and close fast and easy and privacy. I wanted a door that could have some kind of screen for ventilation. I ended up using the camper door from the donor camper as a starting point. I ended up cutting the door down about 3” and completely rebuilding the door in the process. This took two days. Here is a picture as I started my door build.

Now at this point I need the rear glass removed. I am at the point of no return now. I remember thinking, if this does not work, I will have a giant pile of crap!! I proceed to remove all the rivets that hold the rear window and frame to the shell. I then build a header panel above the door opening that spans the width of the camper. This header panel is also 2 ½” thick. And this works out to be the thickness I needed to make up the difference in the Flippac that I started with. It came from a Chevy and was too short for a SuperDuty. Now my planning is paying off. Its looking like it’s going to fit perfect. As a matter of fact, it was a very good thing I started out with a cap that was to short. Otherwise there would have been no room to build the door. This header panel also holds larger bolts that go to the hammock sleeping area. This vastly increased the capacity of this sleeping area. Once just for kids, it can now support 200 lbs easy!

Here is were I get so busy I forget to take any pictures!! Same with the jacks, no pictures during the build. sorry! I need to build in the door now. I frame in two 2x4’s on each side and one on top. The one on top ties into the large header above the door. The two on the side tie into the floor and the side walls. I then frame the wood with 1 ½” metal. I miter cut the corners for a good look from the outside. Made for a nice weather tight seal too. I then make a door stop for the lock on the door. Adjusted the door and screw it in. I picked up some automotive weather seal for all four sides of the door. It’s a nice dry fit! The door shuts with just a light push with your finger.

In this last image, you can see the filler pieces I made that go on either side of the camper. They had to be the contour of the outside edge of the cap and took some time to get just right. All of what you see from the back is now ready to be skinned over and enclosed!!!

 

[Rexsname]

I'm just Sooooo impressed by your vision, imagination and skill. :wings: Very, very Wow!


REX

 

[4x4v8]

Question:

How much will it have cost you in the end to make your camper as opposed to buying one? Will you have saved money or is it just to say that you made it?

 

[Bella PSD]

Question:

How much will it have cost you in the end to make your camper as opposed to buying one? Will you have saved money or is it just to say that you made it?

Cost was never that big of an issue. I wanted something very specific that was not commercially available. I had the pop up camper before this build and really liked it. It's the one in post #43 that was hit by a falling tree. I bought a pop up camper so I could still have the outdoors feeling (tent) and not feel like I am closed in.
After the tree falling on that one I tried to rebuild it. Lost cause, for sure. It was a mess. And I learned how poor theses thing are built!
So I went in search for my next camper. I 1st looking at transferring all the components from the totaled pop up to some kind of trailer. All the trailer ideas never panned out.

I then bought a roof top tent and it was just to small for my family and not all that practical for my needs. Although I did like the roof top tent. I may try to use it some how, on a trailer??

Then I discovered the Flippac!! I thought perfect, except I want a door, floor, interior, self contained and so on. And then the build began.

As far as cost, I have done all the work myself and I am up to $1,100 even. That includes the cost of the used flip, delivery 2,200 miles and all the fiberglass work I will post about later. I also purchased a Norcold 60L fridge with a transit bag that was used for $480.

 

[suntinez]

Louie thanks for the new pics! Been wondering how you got those jackstands in, and a bunch of other stuff too. Your truck and flippac are awesome. :sombrero:

 

[Bella PSD]

In the next few pictures you can see the skin going on. The interesting thing about 2/3 of the wood that went into the camper is that it is red oak. And the red oak I used came from the very pews in the church where my wife and I were married. And I mean the front pew we sat in that very day…Pretty cool, if I say so myself!!

All the skins are ¾ red oak that are screwed and liquid nailed down. I guess I should call the red oak the sub skin, because after this they get coated with fiberglass. It seams a shame to cover up such beautiful oak wood. It does feel good to have the camper all closed in now. Let the rainfall, I'm ready!! I also designed a 3”x3”x4' space above the door for an awning. Its hard to see in the picture, but its there.

I am planning one access door on either side of the main door were the turn buckles are. The access doors will hinge closed, key lock and fit flush with the taillights.

The turn buckles you see in the pictures are temporary ones. The bigger turn buckles will go in when I get the 3/8" steel plates welded up.

Next will be the BIG test for removal. So far the camper has not been off the truck since I started. So these jacks NEED to work. Stay tuned…..
Louie

 

[VikingVince]

Nice work, Louie...love that rear door!

 

[allochris]

that white door needs a custom airbrush job to match the beautiful oak wood colour scheme. :ylsmoke:

 

[Bella PSD]

And here it is on its first test run with the jacks. The camper came right up and off. Next is the dreaded fiberglass!

Louie

 

[Outback]

This is a great idea you had! More pics please!:wings:

 

[Bella PSD]

With the first removal of the camper from the truck bed a success, I am moving on to improving on the stability of the removal system. Plus adding a place for tie downs. If you remember from an earlier post, the tie downs up till now, have been temporary ones.

Here are the four inside jack brackets before they are mounted into the camper at all four corners. They are made from 3/8-inch steel plate bent two times at 90 angles. These bends will contour the inside of the camper. The brackets will be bolted down to three surfaces and the jack tubes will be welded to these brackets as well. Running through the center of this steel plate is the eyebolts for the four turnbuckles that will mount the camper to the truck.

I feel I need to mention that the steel plates are the biggest part of the safety of the entire camper lifting system. Without the support from the steel plates, the jacks move around freely and eventually, if left this way, would completely destroy the integrity of the way the jack tubes mount through the camper wall. The plates are also the backbone of the tie downs that will hold the camper in place. This is another turning point for the camper build. If this does not work, it could be a major set back. And never doing anything like this before, I have no idea if it will really work…..

As soon as they are mounted inside the camper, I will get some more pictures. I understand that I may not have explained this too clearly at this point but after its mounted and I post some more pictures it should be clear what I am up too.
Louie

 

[Bella PSD]

Here is the jack bracket installed on the left rear corner of the camper. The pin resting on top of the tube is used to secure the jack in place. There will be two place to secure the jacks; One for travel, up close to the body of the camper and one moved out away from the camper for stability when removing the camper. Think of it like an extension that moves the jacks out 8 inches on all four corners. I will also make some kind of cap to cover the tube when I travel without the jacks.

The nut and bolt on the top middle are for the eyebolt that secures to the turnbuckle. And below this is a 3/8 aluminum sheet.

 

[Bella PSD]

In this composite, you can see the camper being driven off half way. Then completely free, and in the last image, being dropped down. It is being dropped down onto a special dolly I made for rolling the camper around the drive and garage. So far I can push the camper around no problem, although it can pick up speed going down my inclined driveway!

As for the removable jack system….its a total sucess!! It just works and works good. I mentioned above that may driveway has a slight incline. Even on an incline the camper and jacks feel stable, so I would consider my drive the worst place too remove the camper. Anywhere else I may want to remove the camper and I will look for level ground.

One thing to keep in mind is that the top of the bed on the Ford is right at my shoulder (5 feet 6 inches). When the camper is lifted up its up even higher than that at about 6 feet. Its hard to see in the middle pictures, but its WAAAAY up there!!

You may have noticed the camper changed colors. It did and during this step I don’t have any pictures. But I will go into the details of how I did the first layer of fiberglass and sealing of the body of the camper in detail later.

 

[VikingVince]

You're quite a fabricator, Louie. Amazing how that comes off AND you can move it around. You've taken the Flippac to a new level!!

 

[chnlisle]

Absolutely beautiful job. Man do I wish I could fabricate like that or even close to that.