Homemade Wildernest?

[chazjwest]

Anyone on here have any info or pics on building one? I have a 2005 double cab Tundra with a cab high shell on it already, but my wife wants standing room when we camp in it. I showed her the Flip Pac and Wildernest and we both like the idea. However, finding one at a reasonable price that will fit a double cab Tundra is near impossible. I want to keep things as light and cab high as possible, so a cabover pop up is out.

My plans so far are to build my own Wildernest style cab high shell. I'm planning to frame it with 2x4's and use plywood for the top. Everything will get fiberglass cloth and resin. I'm thinking that I could find a used fiberglass shell off CL and chop it up for the side panels and rear window. All joints will get deck screws, liquid nails and fiberglass. Once the body of the camper is done, I will coat it in herculiner. The interior will just get headliner. The plan for the tent will be to buy canvas and have an upohlstery shop stitch the pattern together and the windows. Galvanized conduit should work for the tent poles.

I think the Wildernest design will be easier to construct than the Flip Pac because of the hinge and support method. The only problem will be working out a way to raise and lower the top without it slamming down when deploying the tent. Also, I don't do a lot of off roading now because my truck is 2wd so I think the wood framing will be alright in my case. Any suggestions, pics, info will be greatly appreciated! Thanks!

 

[UK4X4]

If your planning resin and cloth you should not need 2x4 construction
Ply too can small sizes 6 mm for example

 

[DaveInDenver]

If your planning resin and cloth you should not need 2x4 construction
Ply too can small sizes 6 mm for example

WilderNest used a boxed steel skeleton with wood bracing in a few places (the mount rails for example) for the frame and a lay-up of 1.5 ounce fiberglass mat in the laminating resin with an outer gel coat. It's substantial because all the strength is in the walls as the lid flips open leaving a great big hole in the top. The lid itself is just wood reinforcement (for example for rack pads, latches and hinges) and 1.5 ounce fiberglass mat. There are 5 hinges down the side and two 3/16" cables to transfer the outside load over to the non-hinge side. The whole thing weighs about 350 lbs.

 

[chazjwest]

WilderNest used a boxed steel skeleton with wood bracing in a few places (the mount rails for example) for the frame and a lay-up of 1.5 ounce fiberglass mat in the laminating resin with an outer gel coat. It's substantial because all the strength is in the walls as the lid flips open leaving a great big hole in the top. The lid itself is just wood reinforcement (for example for rack pads, latches and hinges) and 1.5 ounce fiberglass mat. There are 5 hinges down the side and two 3/16" cables to transfer the outside load over to the non-hinge side. The whole thing weighs about 350 lbs.

Maybe I will look into steel framing the shell then with 1" square tube. Especially with that load going to the opposite side. What is the best method for securing fiberglass panels to the steel tube?

 

[DaveInDenver]

Maybe I will look into steel framing the shell then with 1" square tube. Especially with that load going to the opposite side. What is the best method for securing fiberglass panels to the steel tube?

The frame is molded inside the fiberglass, so it's not secured as such. You would want to make sure the steel is clean, no oil or anything, so that the resin adheres to it. Topper shells are made in molds, in reverse. First is sprayed in mold release, then they sprayed in the outer gel coat (the smooth, colored part), followed by a layer of structural 'glass. WilderNests have additional steps of putting in the frame and another layer of fiberglass.

FWIW, polyester resin and gel coat are about $25 per quart, 1.5 oz fiberglass mat typically runs about $0.50~$1 per sq-ft (cheapest to get a whole roll, which is 48" wide by 80 yards at about $250), MEKP is about $3/ounce. My guess is it's going to be at least a few hundred dollars in materials starting from scratch. Don't be shocked when you get a quote for the tent, particularly being a one-of creation. I bet you spend better than $2K making the whole thing.

As a comparison, back when WilderNest was still around they sold for about $3,500. That was the late 1980s and early 1990s and they weren't able to stay in business at that price. Now they'd probably have to charge twice that and have the shells made in Mexico rather than Kansas and the tents sewn in China rather than Colorado.

 

[austintaco]

I am all for making something new, but I would spend some time looking on here, searching craigslist via dailylister or searchtempest, and other classifieds, and if you find one that will fit, go get it. They do come up. However, I don't know if a Wildernest was ever made in your truck's bed size.

 

[DaveInDenver]

I am all for making something new, but I would spend some time looking on here, searching craigslist via dailylister or searchtempest, and other classifieds, and if you find one that will fit, go get it. They do come up. However, I don't know if a Wildernest was ever made in your truck's bed size.

I'd either modify a standard topper that does fit or remake a used Flippac or WilderNest. It's not impossible but fabricating molds or forms is going to be PITA. That's why I'd start with something used from Craigslist, a regular topper that does fit the bed right and then go about reinforcing and doing the changes.

 

[chazjwest]

Thank you very much for the info. I was figuring around $1500 originally, if all went well, but probably would be closer to $2k. The only reason I would even begin a project like this is because of my truck's bed size and trying to find a camper to fit. I might just have to be patient and wait for a Flip Pac to come available. Do you know if the Flip Pac is just a standard size full size short bed or longbed, or if they're custom made to each truck?

 

[bob91yj]

Why not just make a tent room off the back of your existing shell? Use the bed of the truck as the sleeping area, and a stand up tent room off the back. I used to do basically the same thing, I had a $40 screen room that I would set up off the back of my truck.

My set up was obviously pretty crude, but it worked surprisingly well to keep bugs out (when the zipper was closed), and a fair amount of weather protection. A custom enclosure that is freestanding/not dependent on the vehicle that meets your wife's needs would be an easier solution IMO. Using the bed of the truck as the sleeping area worked great for us, it was truly weather proof, no matter how bad it got outside the sleeping area wasn't going to collapse from the wind or start leaking.

I'm in your area, high profile tents and the desert winds that we get can make for some miserable conditions. Not sure that your conduit plan is going to have the strength to hold up.

 

[Clutch]

Why not just make a tent room off the back of your existing shell?

That is what we do (I had a Wildernest and sold it), we have a professional EZ-UP model...with both solid and screen walls.

We usually just do base camping and don't do drive, stop, camp, drive, stop, camp, drive, stop, camp, drive, stop, camp...type of vacations. Usually one long to push to get to a destination...I can usually drive 24 hours straight if needed. My biggest complaint with the Wildernest (other than being ugly)...is being attached to the truck for sleeping/changing clothes whatever. So when I wanted to go find a fishing hole, explore the local area, run get supplies, fetch a broken down dirt bike, etc...I had to tear down the thing, unorganized the sleeping area ...just to turn around and set it back all up again.

For me, that aspect got old real quick...

With an EZ-UP...set up the sleeping quarters and what-not in it, and when I have to go run to do something...simply drive away. No fussing.


Chazjwest: Ever think about just getting a roof top tent....they can be had in your budget. Also have to consider your time involved building such a project, for me
my time is valuable...I can make much more money at my job and in less time, than wasting that time working on a project trying to save a "couple bucks".

Plus you can spend more time in outside enjoying the scenery, than sucking resin fumes.

Toss on a RTT and go...

 

[DaveInDenver]

Truly beauty is in the eye of the beholder, Kermit.

 

[DaveInDenver]

Not sure that your conduit plan is going to have the strength to hold up.

FWIW, EMT is /exactly/ what WilderNest used for their internal tent support poles. The elbows are copper plumbing painted silver. True story.

 

[Clutch]

Truly beauty is in the eye of the beholder, Kermit.

In-deed it is. Never did come to terms with the angled rear window. Broke the glass twice from rocks pinging off my moto-trailer.

It was the function that did it in for me, didn't like "camp" being attached to the vehicle...some go great lengths to dig themselves in...

 

[DaveInDenver]

In-deed it is. Never did come to terms with the angled rear window. Broke the glass twice from rocks pinging off my moto-trailer.

It was the function that did it in for me, didn't like "camp" being attached to the vehicle...some go great lengths to dig themselves in...

That they are rather specific is part of what did them in. Dirt bag skiers, cyclists and mainly climbers love them. Normal folks, yeah, not so much. The angled rear window is only a problem on the small trucks, which is really only like 87.3% of them. Having a full length mattress is worth the weirdness.

 

[Clutch]

That they are rather specific is part of what did them in. Dirt bag skiers, cyclists and mainly climbers love them. Normal folks, yeah, not so much.

Odd that the Flip-Pac seems to doing so well now, and cost twice as much. (That thing is rather fugly as well)

Kinda like the how Microsoft tablet failed in 2002, and the now the iPad sells like crack to addicts.

All about timing, I guess.