Just read your whole thread. I can't wait to get a pop camper. We went to the RV show this weekend in Sac and my wife is 120% on board to get one!! I do have a few questions for you if you don't mind:
Do you ever wish you had the 800 model? I know its longer and extra weight, but is the additional 12"-18" something that would make a difference during wet or snowy camping?
I dont think about it too much, it fits our truck, and the 800 would not. Im sure a little more space could be used, esp. as our daughter grows and wants a friend along. But, again, this is why we have a pop-up, keeps it simple, tight, and somewhat light. Keeps us outside more than in.
Towing: how safe did you feel towing with a hitch extension? We have a 20' ski boat that we would like to take to some more remote lakes.
Hitch extension feels fine, I trust it 100% with the weight i have behind or on it. Mine is only a 14"er. I have a car hauler that i have put behind it with a 5K crawler on it, no issue so long as the trailer brakes are working. Its purdy standard practice for truck campers that travel to shows, think equestrian, and take a trailer. They have extensive weight behind them.
I noticed your trip to KOH you had a bike on a hitch carrier. How how safe did you feel with that additional tongue weight and hitch extension? My old 04' Tacoma with OME Dakar leafs & Camburg CO didn't handle my bike hitch carrier (loaded with a YZ250F) worth a crap, sometimes hitting bumps I felt like my frame was going to fold in half. We upgraded the Tacoma to a Chevy 2500 Duramax (w/ 6.5' bed), so we could essentially do a TC650 or TC800. I'm not really worried about overloading the new truck, but just don't know how safe I feel with a bike cantilevered further out with the hitch extender.
Also what tie down system do you use? The happyjac seem to be the easiest, but I'm not sure if I want those taps between bed and cab sticking out all the time. I've heard great things about torque lift, but I feel like the extension bars would just get in the way when you are off the beaten path.
I use the Happijac rear bumper cleats and twistlock bars, works perfect on a rigid bumper and still has some flex- the OEM tin bumper flexed quite a bit offroad, close to causing damage.
For the front i am using 2" W HD ratchet straps that are attached by d-ring at the frame between the cab and bed, run between and up over the top of the camper jack mount, then D-ringed to the standard tieoff bracket on camper. The strap allows for quite a bit of flex while the truck is bouncing around, I think it really helps keep the camper from tearing itself apart on washboard roads and rutted/rocked out trail.
By the way, seeing your Tundra build I am missing my old Taco.
Im addicted to TOYOTA