After months of no luck finding a Flip-Pac to fit my 2005 Double Cab Tundra, I decided to "sort of" build my own. I came across a used one for sale by a user on this forum and originally decided to clean it up and paint it to match my truck. We made the drive from San Diego to Simi Valley to pick it up for $1000 and squeezed in a Disneyland trip to satisfy my wife and 16 month old daughter. This Flip-Pac turned out to be the original prototype. http://www.expeditionportal.com/forum/threads/81372-The-Original-FlipPac-Prototype Unfortunatley, when I got it home and further inspescted it I realized there were way more repairs needed to the body of the camper than I had thought. A lot of rot and some damage to the actual structure of the camper. Not to mention, it did not really fit my truck very well at all. So, despite realizing that I was about to take apart the #1 Flip-Pac, I dove into the project with the goal of retaining the top and building the body of the camper to fit my truck.
I removed the top that was only held in with rivets to the inside and outside panels. Close measurements were taken and the top was set aside. Then came 2x6" bed rails, 2x4" corners, 2x3" center uprights, 2x2" top rails, 1/4" plywood sides, 1/2" plywood front, and a 3/4" plywood rear SUV style hatch. Everything was glued, screwed, and coated with resin. All exterior joints got 6oz. fiberglass cloth tape. Then came a couple coats of Herculiner truck bed coating on the exterior and interior structural members. Auto carpet was installed on the interior flat areas. The windows were taken from a free shell off Craigslist and I purchased a window door for the rear from a teardrop trailer website. I made supports for the rear hatch and front out of electrical conduit and bimini ends. The interior is lit by 6 LED puck style lights that run on AAA batteries and have a remote that turns them all on or you can press each individual one for on/off. Thermal curtains were used on the windows. The bench seat serves as seating, under area storage, and a step into the top bed. It's supported by a removable table leg and rests on the bed rails. The back rest for the bench rests against the window and can be removed for full access to the cab when the window on the Tundra is rolled down (one of my favorites about this truck)!
We just got back from Agua Caliente near San Diego for a test run and it worked perfectly! I was worried about the black body making it too hot, but with the windows open it seemed to be fine with outside temps in the 90's.
I still have to finish making the hammock for when the Flip-Pac is folded closed. My goals are to construct a solar system that charges a marine deep cycle for small electical and a shower pump. Also, a cassette toilet that is stored under the truck and removed when camp is set up. Any links or advise would be greatly appreciated! Thanks for looking!
I removed the top that was only held in with rivets to the inside and outside panels. Close measurements were taken and the top was set aside. Then came 2x6" bed rails, 2x4" corners, 2x3" center uprights, 2x2" top rails, 1/4" plywood sides, 1/2" plywood front, and a 3/4" plywood rear SUV style hatch. Everything was glued, screwed, and coated with resin. All exterior joints got 6oz. fiberglass cloth tape. Then came a couple coats of Herculiner truck bed coating on the exterior and interior structural members. Auto carpet was installed on the interior flat areas. The windows were taken from a free shell off Craigslist and I purchased a window door for the rear from a teardrop trailer website. I made supports for the rear hatch and front out of electrical conduit and bimini ends. The interior is lit by 6 LED puck style lights that run on AAA batteries and have a remote that turns them all on or you can press each individual one for on/off. Thermal curtains were used on the windows. The bench seat serves as seating, under area storage, and a step into the top bed. It's supported by a removable table leg and rests on the bed rails. The back rest for the bench rests against the window and can be removed for full access to the cab when the window on the Tundra is rolled down (one of my favorites about this truck)!
We just got back from Agua Caliente near San Diego for a test run and it worked perfectly! I was worried about the black body making it too hot, but with the windows open it seemed to be fine with outside temps in the 90's.
I still have to finish making the hammock for when the Flip-Pac is folded closed. My goals are to construct a solar system that charges a marine deep cycle for small electical and a shower pump. Also, a cassette toilet that is stored under the truck and removed when camp is set up. Any links or advise would be greatly appreciated! Thanks for looking!
