Seeking advice/feedback regarding flatbed fabrication for small camper

bajadulce

New member
Hi. :)
Long time follower and member of this great site, but mostly just a lurker.

I have a small camper that rides piggyback on an 8' flatbed platform. It's a relatively light rig. I say relatively light as it uses some older technology such as a chop-gun fiberglass shot into a mold and has some rather large and heavy windows. Basically this is a modified 18' Sunrader that has been shortened by about 2 feet as well as a slew of other body modifications that greatly enhance the usability of the rig while practically eliminating potentials for leaks or annoying maintenance needs. It's a great little camper despite some of its short comings and happy with how it turned out. If I could do it over again or build a shell from scratch, it would definitely be lighter and use smaller and more modern windows.

Here's a few pictures of the camper for reference:
halvedtop.jpg

jakedup.jpg

homedepota.jpg


The first truck was a 1994 Toyota 3.0L V6 4x4. GVW with myself + camper & most of the gear was a whopping 4.5K lbs, but under the GVWR of vehicle with some decent wiggle room remaining. Not heavy compared to other toyota motorhomes, but definitely not light. The flatbed on this truck was built as low to the frame as possible with wheel well boxes and voids in the frame for wheel travel. The wheel well boxes are removable and the camper shell has its own fiberglass wheel wells that fit over these voids in the frame.

bags04.jpg

truckbed.png


My next truck is a 1995 Toyota T100 3.4L V6 4x4. While this truck isn't a heavy duty truck such as an F350, or even F250 for that matter, it is definitely "bigger" and this should provide a little better camper/truck proportions. The 3.4L plus engine bay room being a much desired improvement over the cramped and infamous 3.0. The cab is slightly taller as well requiring new mounting elevations.

t1002.jpg


On to the question and point of this thread:
While the low slung old design with wheel wells worked great in helping keeping the CofG low as well as the gap between cab roof and overhead bunk, it would be really nice to be able to do away with the wheel wells and build a true flatbed for the new truck. I haven't taken the bed off the new truck and backed it under the camper, but from some rudementary measurements, it appears will be able to pull this off with a little compromise in the cabover gap + wheel travel.

I should point out that this particular year truck has 15" wheels and newer years used 16" on the same chassis/body. And so as seen from the pictures, there is a lot of room in the wheel wells. A whopping 13.5" to be exact. And so plan to keep the 15" wheels to allow for a closer flatbed. I have a set of firestone air bags + can add a leaf if necessary.

Invariably there's going to be some give and take in terms of the cabover to roof gap and wheel travel, but what should a minimum wheel travel range be? Would 10" be sufficient? 8"? And any suggestions on how one might go about testing to find out how little wheel travel is needed for a particular application?

I should add that I am a conservative driver (friends say I drive like a little old lady haha) and try to avoid hitting big potholes/bumps at high speed. But these things are unavoidable. The occasional brief tire rub from these rare events prob wouldn't be too much of a concern?

Thanks for the audience and any feedback is greatly appreciated.
Steve H.
 

AeroNautiCal

Explorer
Can't help with your query, but I just wanted to say that I love the way that you've reconfigured and upgraded the camper body to suit your individual vehicle characteristics! happy0034.gif

Do you have any interior shots?
 

bajadulce

New member
Sure np. The interior is about as simple as it gets as you can imagine for such a small space. I don't have a lot of pictures of the interior and I'm not much of a photographer but here are a few shots taken from mid construction. The interior walls are made up of rigid insulation and FRP panels. The cabinetry made of about equal parts of 1/2" and 1/4" birch plywood.

Some basics:
  • Overhead cabinets on both sides of the small galley and across the back
  • 2 bench seats with storage underneath (accessible from outside compartment door as well).
  • a small counter top for a portable 2 burner stove + some drawers and a few other misc cabinets. fake vinyl floor tile for counter top btw. was cheap!
  • a small removable dining table with a piece of clear lexan clamped to it. Kinda luxurious looking and easy to clean!
  • a small 400 watt inverter for the couple of outlets you see (Blender and Laptop etc). Very small need.
  • a solar charger + 150 watt solar on roof + a decent sized gel battery (under the step to bunk area up front)
  • a few basic elements like florescent lights and a radio etc.
  • nice full size one-piece foam mattress

reari.png

counterj.png

bunkstep.jpg


One thing missing is a fridge. I have a nice marine flip-lid type, but there currently isn't a good place to put it. Hopefully that will soon change with the new truck and true flatbed by doing away with the wheel wells inside the camper (under bench seat and cabinet). The right bench seat will be shortened a bit and the fridge will become an extension of the bench. So am very anxious to get the new flatbed worked out.

The roominess of the camper always surprises ppl when they step inside. The camper doesn't look very big on the outside, but it's relatively roomy inside. There is quite a bit of storage space as I have no plumbing nor sewage holding tanks etc. One concern is it is really easy to start filling up all the cabinets with gear. The more cabinet space you have the more junk you seem to cram into them and am constantly monitoring my weight.

Hopefully I'll have the truckbed off here soon and will have a better idea of the challenges with flatbed. Been looking at a lot of different examples on the internet, but really would be nice to check some out first hand.

Thnx for the compliments. It's a fun rig built on the cheap and whatever materials jumped up at me.
 

mextripper

New member
Love it! Good interior, like your cabinets.
I'm laying the last two sections of glass on mine this weekend, see post by mextripper I Need A Road Trip and in Member's Albums.......
 

IdaSHO

IDACAMPER
Invariably there's going to be some give and take in terms of the cabover to roof gap and wheel travel, but what should a minimum wheel travel range be? Would 10" be sufficient? 8"? And any suggestions on how one might go about testing to find out how little wheel travel is needed for a particular application?


Steve, first thing you need to do is measure the distance between the leafs/axle and the chassis mounted bump stop. This will give you an idea of how much compression is actually available with your exact suspension and tire setup.

I take that number, and add 25% That gives you ample room even when bottomed out and flexed. It also give you the ability to run snow chains without destroying things. Something I will not live without.

So if you have 6" of distance unloaded between the axle and the bump stops, figure on needing 7 1/2 inches above the tire in the wheel well (unloaded). That way fully compressed you still have roughly 1 1/2 inch of space between rubber and steel. :ylsmoke:
 

tanglefoot

ExPoseur
Great work with the shell and interior, and nice find on the T-100 long bed with a 3.4...it seems like most of the long-beds had the 3.0.

I'm sure you'll have a better idea of the clearance needed once you remove the bed. If you plan to use the camper on trails, you can strap some weight to the back frame to simulate the weight of the camper and then find a way to flex/compress the rear suspension to measure how much room you'll need (be careful not to roll the truck!) You'll need more space than just the distance from the axle to the bumpstop if the other end of the axle is drooping. Allowing extra space for mud/ice buildup/tire chains is always a good idea, as mentioned above.

Just a note that wheel size and outside tire diameter are completely independent. The latest trend has been towards larger-diameter wheels but overall tire diameters have not necessarily increased--tire sidewalls are usually shorter on larger wheels. You can put 44" (monster) tires on 15" wheels or you can put super low-profile 24" tires on 19" wheels.

I'll be watching this. Toyota campers are dear to my heart. My parents' family camper is an '88 Toyota Odyssey motorhome and I have a truck camper on an '85 Toyota...both with 2.4L engines.

Oof--I just realized this was from 2012. I thought it was 2013. Oh well...see if you're still around.

Eric
 
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