To pop up or NOT to pop up

[SuperAwesomeDOOD]

Given virtually every other hardside build shown on this forum and the time needed to complete their builds your statement above WILL NEVER HAPPEN!

That may be. I’m hoping to just get the shell completed in that amount of time. I built the 24x24 addition to our house in 60 days by myself including hand digging the foundation before I owned an excavator, but I also took two months off work. This will be a nights and weekend sort of affair.

 

[rruff]

I’ve also thought about fiberglass options. It doesn’t seem doable for me. The area I’d be working with epoxy, resin, sanding etc is not temp controlled. Curing may be an issue. Also, I need to be able to work on the camper in small chunks of time. Working with fiberglass is fairly time sensitive. Lastly, material handling working mostly alone can be quite difficult. I live in the sticks and it’s not feasible for someone to drive 45 minutes out to my house to help for an hour or two.

You don't need temp control for epoxy, it just needs to be warm enough to cure. I used the slow cure for everything even in winter (avg daily temp range low 20s to high 40s) and just threw a plastic sheet and cheap electric blankets and comforters over it once it got sorta solid. The blanket raised the temp ~50F over ambient.

It is best to to get all the layers done in one go, so you don't have to sand in between... but you can also use peel ply. But... if you want a really nice smooth finish, this is hard to do with hand layup, at least for me. I don't think it's worth the bother unless you want curves and such, and you won't have that with an exoskeleton.

You can buy panels already made from Carbon Core, with the PP honeycomb core. https://www.carbon-core.com/product/composite-panels-sheets/ Price is quite reasonable. The downside there is poor insulation compared to foam. The Everlander build (https://everlanders.com/build/) used these or something similar.

If you want to build your own panels, I'd suggest PVC foam from Carbon Core. It's much stronger and glues better than XPS. When I bought from them, freight shipping was a flat ~$350, or free if you ordered enough ($2-3k in one order?) https://www.carbon-core.com/product/pvc-structural-foam-sheets/

Check out this place for the FRP sheets. https://www.vetroresina.com/en/product-category/g-force-j-force/ The US plant is in Greenville SC, and I know of a couple people who have used them. They have options that are very robust.

Do you have any family members who can help move things around?

Also, what year is your truck? Does it have a boxed (stiff) frame? Payload?

I wouldn't be shy about making your cabover as long as your cab. Make it so you can sleep fore-aft, and have lots of room.

I think you can get the shell done and mounted in 6 months if you are focused and diligent... not lazy like me!

 

[rruff]

What is your budget on this? I saw $10k mentioned earlier. That's probably ok for the shell, but a full build with typical amenities will be way more than that...

 

[SuperAwesomeDOOD]

Imho.. you're going to need a higher budget.
Now might be a good time to do a little price checking/ comparison on materials and tools for whatever framing material.
As noted, burn out is a high probability.

I’m squared away on the tools. My take off is complete for the shell. Roughly 230’ of steel tubing or twelve sticks, a few pounds of welding wire, 15 sheets of 4x8 inside (most likely luan) and about $1500 worth of exterior skin.

Waiting on my local metal supply to open tomorrow to get steel prices. I’m guessing roughly $50-70/stick for the steel.

 

[SuperAwesomeDOOD]

You don't need temp control for epoxy, it just needs to be warm enough to cure. I used the slow cure for everything even in winter (avg daily temp range low 20s to high 40s) and just threw a plastic sheet and cheap electric blankets and comforters over it once it got sorta solid. The blanket raised the temp ~50F over ambient.

It is best to to get all the layers done in one go, so you don't have to sand in between... but you can also use peel ply. But... if you want a really nice smooth finish, this is hard to do with hand layup, at least for me. I don't think it's worth the bother unless you want curves and such, and you won't have that with an exoskeleton.

You can buy panels already made from Carbon Core, with the PP honeycomb core. https://www.carbon-core.com/product/composite-panels-sheets/ Price is quite reasonable. The downside there is poor insulation compared to foam. The Everlander build (https://everlanders.com/build/) used these or something similar.

If you want to build your own panels, I'd suggest PVC foam from Carbon Core. It's much stronger and glues better than XPS. When I bought from them, freight shipping was a flat ~$350, or free if you ordered enough ($2-3k in one order?) https://www.carbon-core.com/product/pvc-structural-foam-sheets/

Check out this place for the FRP sheets. https://www.vetroresina.com/en/product-category/g-force-j-force/ The US plant is in Greenville SC, and I know of a couple people who have used them. They have options that are very robust.

Do you have any family members who can help move things around?

Also, what year is your truck? Does it have a boxed (stiff) frame? Payload?

I wouldn't be shy about making your cabover as long as your cab. Make it so you can sleep fore-aft, and have lots of room.

I think you can get the shell done and mounted in 6 months if you are focused and diligent... not lazy like me!

Frame is fully boxed. Sticker payload is a little north of 2k right now. Only difference between 2500 and 3500 Long bed Crew cab 4x4 SRW in this generation Ram are springs. 3500 payload is well into the 3000lbs range (~3400lbs iirc). Not that I’ll be anywhere near that.
My new rear springs, which I’ve yet to install are full progressive Carli leafs designed for a constant 1500lbs in the bed. I may or may not run airbags as well with the springs depending on what everything feels like once complete.

 

[rruff]

That makes mounting easier. Are you planning on making it a slide in, or flatbed style?

 

[SuperAwesomeDOOD]

That makes mounting easier. Are you planning on making it a slide in, or flatbed style?

I’m leaning towards building a flatbed, but not one that sits entirely above the tires. I’d frame wheel well openings and put truck tool boxes fore and aft. That’d give me the lowest roof height possible and really easily accessible storage.I guess that’s not really a ‘flat bed’…

In other words, build it in a way that doesnt change bed floor height, but has higher openings for wheel up travel.

I’m looking at this as an option, too. It’ll get me outdoors much quicker:

CPT Truck Utility Box vs. Tufport

Anyone have feedback on either of these? CPT: https://www.cptpanels.com/wp-content/uploads/2014/03/Truck-Utility-Boxes-New.pdf Tufport: https://wasatch-overland.com/truck-slide-ins

expeditionportal.com

 

[rruff]

How much are those CPT boxes? I see they also sell panels, so something more custom might not be bad: http://www.cptpanels.com/

Regarding wheelwells and height, you might want to talk to the wife regarding headroom in the berth. I found that decent berth height (~35" with no mattress) meant I might as well have a flat bed. I have 76" interior standing height, which is plenty at 6'. Mine is sort like the Aterra where the side walls are 66" and then there is an angle going up to the roof.

 

[1000arms]

I’m leaning towards building a flatbed, but not one that sits entirely above the tires. I’d frame wheel well openings and put truck tool boxes fore and aft. That’d give me the lowest roof height possible and really easily accessible storage.I guess that’s not really a ‘flat bed’…

In other words, build it in a way that doesn't change bed floor height, but has higher openings for wheel up travel. ...

You might find some inspiration for building your not-quite-a-flatbed flatbed from:

Bowen NotSoFlat Bed Revisited

expeditionportal.com

Camper Bed

Introducing our new Camper Beds! Designed specifically for slide in campers! High departure angle Retains factory bed height Increased storage Aesthetically pleasing! To our knowledge this is the first overland truck bed of this kind, with these features! Features: The bed floor stays the same...

www.bowencustoms.com

In the Spotlight: F350 Hallmark Guanella 'Stormtrooper' Rig

The Overland Expo West is the premier truck camper show in America. New truck campers and expedition rigs are rolled out for this big show every year, and

www.truckcamperadventure.com

 

[SuperAwesomeDOOD]

Thanks everyone for your input.

Pulled the trigger on a TUFPORT. Here’s where the build will take place:

SuperAwesomeDOOD’s TUFPORT build

After much debate, back and forth and mental gymnastics found here: https://expeditionportal.com/forum/threads/to-pop-up-or-not-to-pop-up.236755/ ; I’ve decided on a TUFPORT slide-in shell. The shell won’t be installed until May when it’s delivered to their US vendor. In the meantime, I’ll be...

expeditionportal.com