Utility Shell Pop Up Build

hoptroll

Pool Boy
Hello fellow adventure seekers. Long time listener, first time caller. I have been eying a pop up camper for quite a while now, but they are a bit out of my price range and are all so big and heavy for my little Tacoma. Decided I wanted to build one for myself. I was getting tired of crawling in and out of my cab height shell and having little to no space. I camp in the parking lot at work in between shifts a lot and wanted something with some more space. Additionally, I took my 2nd trip to Baja a couple of years ago and fell in love with it, but camping in my '00 Tacoma for 2 weeks with my best friend got old quick. We needed some shelter and a better place to sleep!

So I started building by brain and collecting ideas from all of the builds I have seen on here. The conclusion that I came to was that it was going to be more expensive and time consuming than I had ever thought. So I went back to the drawing board and decided I was going to get a commercial shell for now due to the increased height, ability to insulate (cold wet nights on the cali coast here), and easier to customize. I found an aluminum ARE shell for $100 on craigslist a 40 min drive away. Even if it didn't fit, I figured I could make a buck on a resale. I bought it and $26 later I had working locks. And then the gears turned some more and I thought I could make a decent little pop up with some more aluminum tubing and such.

So the plan is to extend the frame down, build a floor pack somewhat like the 4wheel campers, and build a simple support structure for the pop up and slide out bed, and insulate it. The interior will be simple, but elegant I think for what I have planned, just some simple storage like this build http://www.expeditionportal.com/forum/threads/52773-Hard-Side-Tacoma-Popup-build. The nose of the camper will be extended 2-2.5' and I think the top will be made out of wood/fiberglass (haven' really decided on this yet, open to suggestions). Going to do hard walls, similar to this http://www.expeditionportal.com/forum/threads/4811-Allochris-s-ultimate-buildup-thread!!! or this http://www.expeditionportal.com/forum/threads/80666-Pop-up-A-frame-Camper-La-Roulotte Would be really happy if I had a finished product that looked like this http://www.alu-cab.co.za/?cat=9

So far I have taken the rack off, taken the front and back panes off as these will be modified, and have the aluminum that I need to make the frame extensions for it. Would love to hear folk's comments and suggestions, as that is why I am sharing. Oh and I should mention that I sprained my ankle really bad about 2 weeks ago, so I have a LOT of time to devote to this right now, no work for prob at least 4 more weeks.

Truck:
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High Quality Renderings:
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Shell:
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Ankle for laughs
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Let's hear what you think!
 

Ozarker

Well-known member
Thinking along the same lines, a popper topper.

Just put a skate on that foot, you'll do fine.... :)
 

bonomonster

Adventurer
I have an FJ cruiser, and have been planning and looking for a Tacoma to turn into a trailer and do something very similar.....Subscribed
 

hoptroll

Pool Boy
Moving Forward

Got some time with the welder today, using a friend's TIG setup at his commercial shop. Finding shop time has been difficult since I have to work after hours. Got one of the supports done today, thought I would post for visual purposes. Sounds like I will have the shop all day on Monday, which should give me enough time to finish the welding that I need to get done.

PS cant figure out how to get my pictures the right direction.
 

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hoptroll

Pool Boy
Got time on the welder today, but unfortunately it was more of a learning experience than anything. I have never welded aluminum this thick and apparently haven't been getting good penetration because I got the frame home and had broken 4 welds completely and cracked a couple of more. Going to look into using a different welder too because I have been having a hard time coordinating shop time which has caused me to rush which obviously has already caught up with me and bit me in the ***.
 

hoptroll

Pool Boy
Frame Wrap up

So I managed to mostly finish welding the frame today. My buddy got his welder all dialed and it worked fantastic! Miller Syncrowave 350, using argon, 4043 filler rod and the aluminum is 6061 t6. Managed to weld the frame together, go back and add some more welds to places I thought could use them. Had 4 more pieces to weld in between the top cabover pieces and the ceramic cup on the torch got too hot and broke! My friends shop is expansive to say the least, he has everything and can fabricate anything (he has the biggest lathe in the county), yet we couldnt find another cup. So I think I will be going back to wrap up those pieces. I could rivet them with plates, but I think welding will be better. Anyway, the frame is SOLID. Might add a gusset under the cabover portion, but other than that I am pleased. To give an idea of where this is going, the shell will sit over this frame. :rockon:


PS Someone needs to help me with the pictures thing, I cant get them right side up
 

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hoptroll

Pool Boy
More Progress

Got some time in on the camper. Finished resizing the door (no pics not that exciting). Also cut the roof off and started fitting the frame in the shell. Im pretty excited, I really like how the layout is coming along. Also picked up the door from the GCecchetto's old camper as well as the old front window and horizontal propane tank. Still deciding where these goodies will fit in.

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NorthernWoodsman

Adventurer/tinkerer
subscribed! was hiking today detailing plans, in my head, for building a pop-top utility shell for my truck. great minds...
 

hoptroll

Pool Boy
Adventure Day and Camper and frame become 1!

WHew! What a day. Started off by making the drive to visit GCecchetto's to buy the roof and softwall from his old FWC. Lets do the math on that one; GC's old camper was a Hawk, designed for a full sized pick up. I drive a Taco, SIGNIFICANTLY smaller! HUGE shoutout to GC for all of his help this morning!

photo 1.JPG
What a Hawk roof on a Tacoma looks like (upside down of course, unbelievably frustrating)! Only had to stop once and tighten down just one ratchet strap.

The old softwall will be shortened. The windows should fit perfectly on my shell.
photo 4.jpg

And then I moved on to working on the actual camper. Used rivets and brackets that I found at the hardware store to make the shell and my frame one piece. I was very impressed with how well it is all holding together. I also used a couple of sheet metal screws in non critical places (those are the big holes).
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Monday should start making this shell look like a camper. I am going to build the floor and start putting the aluminum skins back on it. I was going to buy ply wood today, but I didnt have room in my truck.
 

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