Overlanding project lab

[realsystem]

Let me introduce a small intro as a part of the climbing video. This is about my new project to replace standard shell and RTT by DIY truck camper. I will post more info later with detailed step by step videos about how to make it.

 

[realsystem]

Not a build video, but has some details about camper







And just one photo for start:

 

[realsystem]

I finished the testing stage of my new custom made camper. Let me explain what is it and how I build it.

The idea was born way before building a truck camper. It was just a thoughts about expedition vehicle capable of doing off-road trails and long road trips across the states. I found Tacomaworld forum and decided to go with Tacoma in 2017. I bought TRD Offroad trim short bed double cab. It's fitted with my needs very well. And I started to build a rig that I really wanted. The plan was to copy what other folks doing, so, I started with rooftop tent on top of the regular camper shell. But it was a big one, Smittybilt XL which should be mounted on the trailer because of heavy weight. I built a reinforcement inside the shell. It's just an aluminum supporting frame connected by angles and rivets. Also, I built heavy-duty roof rack for RTT. I used this setup for a while and even bought an annex. We traveled a lot with my family and this setup was good for sleeping in warm and dry conditions. But I found out that I need something insulated and that can be quickly setup and fold. Also I had concerns about using space inside the shell. I've built a sliding platform with a fridge and stove. But still need more space for camping gear.

This is what we used about two years to travel across California, Utah, Arizona, Nevada, Wyoming, Montana and Idaho.

 

[realsystem]

There was no electrical system and any water source in my setup. And I decided to go with other solutions. After one night near the Yosemite National Park where I was doing snowshoe trails with some Facebook group, I understood what I need. It was just a blurry idea but I started to collect information and finally made a few draft blueprints. It was a slide-in truck camper that can be easily removed from the truck bed when it's not needed. But when I applied real measurements on the truck I realized that it's eating too much space in the bed and I don't have a place to store it. So, I decided to go with a permanently installed truck camper on a bare truck frame. 3D modeling helped me a lot and I figured out how it should look like.

 

[realsystem]

I started my build from 3D modeling because I wanted to make walls and all panels of the box before installing it on the truck. Found a new(for me) material named B-bond which is polyethylene bonded with aluminum on both faces. It's used by sign shops to make outdoor signs and banners. The frame for the box is aluminum square tubes(1x1) and it's integrated to the walls. Insulation is just a regular XPS from Home Depot. For the interior, I've found FRP(fiberglass reinforcement panels). The floor is just plywood on the aluminum frame(1x4). I didn't find any better solutions. The upper frame for the tent is 1x4 aluminum tubes as well. The roof frame is 1x2 tubes.

 

[realsystem]

Thanks for sharing and... GREAT WORK!!!

A couple of questions...

What CAD system were you using?

Were you doing the TIG on the frame in your shop or were you working with a "fab" shop?

If you were working with a shop who was it?

Either way, thanks for sharing and proving that you are a part of this community!

Oh, and another quick question... I see in your first camping picture a woman and a child. Should you be saying we instead of "I"?

I'm using Fusion 360.

No welding, just glue and rivets.

When I talk about traveling with my family, sure, I use "we". But the build process is mostly my responsibility and I use "I". I tried to minimize the impact on my family during the build.

 

[MCX]

Looks great! Thanks for sharing!

 

[realsystem]

What I used for calculations. Spent a lot of time finding the proper information and tried a lot before buying and implementing.

For cushions: https://www.fabric-calculator.com/box-cushions.aspx

For gas struts: https://www.camloc.com/wp-content/u...cal-Guide-Edition-2.0-Gas-Spring-Mounting.pdf

 

[realsystem]

Electrical system: two solar panels Renogy 100W each, prismatic LiFePo4 battery 100Ah 12.8V, solar controller Renogy Wanderer and 20A DC-DC charger. Also installed battery protector(Viktron) to disable load when the voltage is dropped. This setup was tested during the last trip. I have a fridge 110V AC and using 1kW inverter to power the fridge when not driving. Also, use Toyota factory inverter to power the fridge when the engine is running. I have to manually switch the fridge between sources. Need to build an automatic system.

I've built a temperature controller based on ESP8266 and DHT-11. One sensor is installed inside the fridge and the second one is outside. It's trying to connect to wifi on my phone and send information to my telegram bot. It's not fully finished, work is still in progress.

 

[realsystem]

A water source is pretty simple: Seaflow water pump 3 GPM, small accumulator, house filter and 13 gallon water tank. Planning a hot shower later, need to build an outdoor box for it first.

 

[realsystem]

Some details about the basement. I used aluminum sq tubes 1x4 and plywood. Just glued/screwed together and install. For protection, I used Flex Seal rubber for the outside and polyurethane for the inside.

 

[realsystem]

The walls are my own composite: beBond, XPS, FRP. The frame is 1x1 aluminum tubes. Wooden inserts for the interior mount point.

 

[realsystem]

All walls connected with rivets and glue. Aluminum angles everywhere to cover corners. The part above the wheel will be cut later.

 

[realsystem]

For the interior, I used thin aluminum tubes 1x1 and plywood from the previous project.

 

[realsystem]

Testing in the Mojave Desert.