l ended up lowering both front and back wall beam pockets and wrasping the top of the walls front and rear to achieve the right roof contact points. l had several beam pockets that needed to be cut down a little deaper. lt has a 900A jump-starter with built in cables, 120 psi air compressor, 500W power inverter, and 12V /DC outlets and USB ports built into the unit. We then set that wall in place. l cut them off to about 5 ". l tell you this because l was able to find two sheet of foam board each with some serious damage along one edge. l then set the front wall in place and we held the corner together to make a nice outside corner. I put an electrical box in the face of each nightstand using a remodeling box, this will be perfect for a phone charger, or lap top. I'll wait until they are in place to build the tops. We primed and painted the inside of the wheel wells using the same paint and method as the under side of the floor.Since the inside of the wheel wells will take on an extreme amount of water when traveling in the rain I decided to coat the inside with Herculiner bed liner material. Then I'll make foam inserts on hinges to fill the mid sections instead of using canvas. I put both side walls on top of one another and taped them together to make sure nothing moved on me. Now the question is what is the best way to attach the cover to the trailer. Making your DIY fiberglass camper shell is essential if you want to convert your truck into your sleeping space without having to put up a camping tent. I just took a can of spray foam and sprayed it on my bondo mixing board and using a bondo spreader l worked the material back and forth until it was like peanut butter and the using the bondo spreader l buttered the opening. This gave me a pocket at 2', 4', 6' and 8' in addition to the pockets just inside the front and back walls. The new target date is to be done by Memorial day, 2017. 3 1/2 weeks later l drove again 3 hours and 40 minutes round trip only to have to reject the door due to extremely poor workmanship. Then I used 10 foot 2x4's to make a 6' x 10' table frame.Next I built a staging area to stand the 4x8' sheets of foam, paneling, etc all upright so that it remains straight and out of the way.I'm building the walls in two stages. Altair - a Tripod Mounted Refracting Telescope. A word of advice, beware of Frank Bear and Vintage Technologies in Union City, MI. For the roof supports I am bypassing pine 2x2's because of how unstable they are. You need to make sure you can get the wheels on and off easily if you need to. I decided to purchase a custom built door back in mid June in order to save time and hit my deadline objective. I needed the cargo doors, A/C unit, and windows early on so I could plan my wall rough openings. A little filler and sanding and it's looking good.Next l'll cover it with glue, canvas, and paint. He convinced me that he would have my door to me in 2 weeks. We primed the plywood roof using an exterior primer. The frame is in great shape and I think I can part it out to make some of my initial investment back. I want it to be light weight, well insulated against the heat and cold, and I want to pack as much function and comfort into it as possible. To create a homemade camper you want to begin with a whole lot of planning. I chose to go this route for two reasons, first it allows me to sell more parts in the end, and second you can learn a lot about how they built it in the first place. lt's stronger than the pine and completely stable.I used 3/8" plywood for the roof material. This is real birch not a particle board look-a-like. The slats really firmed up the plywood and keep it from having any sag. A hot knife is the best tool for that job. As final prep l used my shop vac to clean all the areas that will be glued. Forget that, I have never seen anyone post a close up picture of a canvas & glue project. I have access to a workshop until then. I purchased some light weight indoor/out door carpeting at Home Depot to cover the plywood so that the mattress isn't just sitting on plywood, plus there will be about 7" on each side between the mattress and the wall. I hope you have many years of enjoyment in your camper. He then told me if l want the door l can come get it and hung up on me. I had to travel 2 hours away to make the purchase. I then set that wall aside and move on to the next. I hunted on the internet to find some good quality, but low cost cargo doors. Deconstruction is taking each part and component off one at a time. lf you over cut the hole you may have issues getting a really solid glue job. I'll need to wash the drop cloth and then cut the edge seams and the center seam out. Thank goodness I made it home with no problems at all with the trailer. The glue companies said not to apply glue over paint and the paint companies said not to paint over glue. Dec 29, 2019 - Explore Bruce Parshall's board "Home Built Camper Shell" on Pinterest. l used the excess plywood to build my drawer boxes. Showers, toilets, battery banks and solar requirements, water storage, sleeping and eating arrangements to name a few. I considering doing something similar using marine epoxy and foam core to build the shell. Don't get me wrong, I think l may build a deer blind using that approach, but anything that l want to look good isn't an option. Remember your working with a finished interior. If so can yo it refer me to those plans...maybe you could send some photos of your trailer. l will highlight that project in another section to give my feedback on the subject. From here l'm using drywall compound to fill all the seams where the walls and the deck come together, as well as the wheel well area, and any other imperfections on the exterior. The last thing l need is to have roof issues because of twisting and bowing supports. FYI - The A/C unit can't be completely enclosed inside the camper without properly venting it if you want it to work right and last any length of time. Once the walls were complete and work on the table had gone as far as l could take it, it was time for a dry fit. We each started laying down glue at opposite ends of the wall and met in the middle. I'm not wiring it with a built in inverter. l tacked the plywood down with 1 1/4" 16 ga. gun nails on the outside edges of the wood cross beams and a few in the center. l used liquid nails for paneling to adhere the foam board to the underside of the plywood roof. I found that several had actually installed them wrong. Nobody wants to wake up early. I used a grinder and power drill to take the surface rust off. l will make this promise to you, l will cover every step in detail start to finish on making this door. They use it to cover the wings of small planes. This is astounding. Did you use plywood on the inner walls? I then looked online at a lot of commercial RV's to see what they were using for style and for the clearance front and back of the tires. The threads of the cut edge of the canvas are also a real challenge. They seem high when you look at them but the mattress is 6" high and a pillow is 3 - 4" high so once the bed is made up they should be just right. I built the night stand boxes using some leftover plywood, the finish size is 6" wide x 21" long x 14" high. I've been looking for sip panels at a reasonable price.....where are you getting them? l used DAP. l need this opening to be precise and 2x4s will bow and twist. 2 years ago, 2 years ago I used my saw and a speed square to cut the edges of the pocket cut outs cutting both walls at one time and making sure to cut plumb and straight cuts. projects…. By working the expanding glue this way it save alot of time later and it makes a stronger wal frame connection. l rounded the edge over just a bit to begin with. They turned out nice. The key here is to not drive yourself crazy trying to get everything to fit perfectly, it won't. Weatherizing your truck cap Step 1: Apply adhesive to your truck cap. I am currious. I spent about 3.5 hours redoing the 2 window openings, and they are now a more snug fit. See more ideas about camper, camper shells, diy camper. You use an old rusted frame that has to be reconditioned. You can't even buy a basic floor plan without a bathroom. l then glued them together and nailed them with 18 ga. 1 1/4" finish nails to hold them in place while the glue set up. Thank you for sharing your obsession. That saved me $21 and l knew going in that the damage would be scrap anyway. With the glue and canvas exterior finish these type of issues may show, so better safe than sorry when it comes to prep work. The glue that has expanded is now set up and rock hard. It could be tighter. I then installed the 2x2's with gorilla glue and I used a 16 ga.nail gun with 2" nails to fasten them in place while the glue set up. l have designed the system with a 2 breaker electrical box. I'm back and committed to finishing the project and enjoying the process. Since both get glued to the paneling all the way across l didn't want to deal with the mess of using gorilla glue. So I had to sand down the wheels use White rust reformer primer and using rust-oleum paint I painted each with 2 coats of paint. Did the windows and doors secure directly through the foam/fiberglass core or did you have to put in a jam to secure to? Sorry but this was crazy. I like your trailer, but have one comment. Still better to have all the info than not...Another key component is the AC unit. Look at the photos of the canvas & glue carefully, you will see every imperfection in the foam telegraph through the canvas. As it turned out, I'm not sure we needed to do the entire wall, but sure as we hadn't we'd of had a wall drip issue. Curious about using drywall compound as a filler. l purchased 3 pieces. Building the frame was an easy process once we … The earliest models were made of metal, however due to premature rusting and weight, the next generation of caps were made of fiberglass. Rather than doing the poor man's fiberglass like l had originally planned to, l have decided to skin the exterior with 1/4 inch plywood which will basically creat a structural insulated panel aka SIPs wall. To build the new wheel wells I used the old wheel wells to give me an idea of how much clearance I should have on the top and sides. The solution was to try to find an old camper with a solid frame. We installed the interior trim rings for the windows. The fit and finish issues can and will fixed during the exterior final prep phase. I learned this technique from going to camper shows and looking under the beds and in the cargo areas. l ultimately turned the matter over to my attorney who sent Frank Bear/ Vintage Technologies a letter asking him to deliver the door to my address in an acceptable condition as previously agreed to or refund 100% of my money back by a certain date. Campers. If the top doesn't look right, I can always rebuild the top. lf you're going to be installing window shades inside you will need to install wood blocking to screw into. Is it just glue? I don't need a bathroom or a shower, the state parks have those...but I do want to be comfortable while I'm camping, especially if it happens to rain...We've gone to the camper shows now for a couple of years and all we see is over priced camping trailers with too much stuff crammed in to a small space. We used a 4" roller to apply to material then back brushed it with a paint brush. I spent probably about 3 - 4 hours total to get it all to clean metal. Once it dries hard in 3 or 4 hours you can carefully take a knife to begin trimming the expanded foam away and then when your close sand it the rest of the way. 3 weeks later l finally got him on the phone after numerous calls went un returned. The original topper roof was then expanded to include hinged, adjustable walls (including windows) and a roof. This DIY guide to installing a camper shell liner, will help you insulate your camper shell, cover up the ugly exposed fiberglass, and keep that condensation from ruining your truck bed camping adventures! I learned this technique from going to camper shows and looking under the beds and in the cargo areas. Question All of the pieces were glued with construction adhesive and nailed together with ring shank nails. Once the walls go up I can push them snugly into each corner and screw them in place. We don’t take that lightly. I appreciate your thoroughness and the fact that you tried this technique on another project first. I will screw the plywood bed top down without gluing it. l installed 12"×12" stick down vinyl floor tile up front for the floor in between the bed and cabinets inside the door. I chose a 5,000 BTU Kenmore, it cost about $115. I'm starting to slowly pick up the pieces and begin my final push to finish this summer (2019).12/19/18 - Things are moving once again on the build. My design would need to be able to drive the truck with the tailgate up but when camping the tailgate would be … Step 2: Mount truck cap on truck bed. My first encounter - They told me that they had the windows that l was looking for in stock and they will ship next day. No one out there has really done any of the how to info or steps on A/C installation so l intend to cover it here. You need to work it for several minutes. I did the 2 sides first and after about 90 minutes I was able to reposition the wall on the table and do the top.Once l finished the first side wall l laid it on top of the other wall and traced the roof line, window, and other cut outs. I live in Owosso, MI now where I lead a more suburban lifestyle during the week. cost was the most important aspect of this project so labor hours didn't matter as much. l finally got the windows by driving down and picking them up. Harbor freight was a great source for big savings on the cost of the tools that I needed to purchase. Because I designed it to be simple with a flexible design that I could “upgrade” once I was already camping, I completed the basic shell and started camping in it after only 3 construction days . I followed the same process for cutting my rough openings and the gorilla glued them in place. That's right, I'm becoming kind of a "Foamie" or at least a "SIPs" inspired builder and this is my project....My goal is to keep the cost (including specialty tools) to $3,500 or less and have the camper completed by mid July 2016 for our annual family camping trip. When you apply it DO NOT apply it like drywall mud where you over apply and feather it out in a larger circle around the fill spot. lf l do camp off the grid l can use this power station. I used scrap materials left over from building the walls of my camper. Thank you for a great Instructable. I'm building a Foam based Teardrop inspired micro camper. I just traced the trim with a sharpie, cut it off, and cleaned it up a bit with my palm sander.Cutting out the window and cargo door rough opening is time consuming. Just fill your spot and keep it in a tight area around your fill spot. Camper shells provide, at a minimum, cab-height clearance for cargo or more. Using plywood or light wooden planks is the most vital part of how to build a lightweight truck camper guide. l used construction adhesive to glue the front and back beams in place. l intend to camp in State park campgrounds mostly and they have power. Once I had a bare frame it was time to get to work. Main reason I am looking at using the 3/4" drywall 1/4 round on the edges. This how-to will show you a quick and easy way to throw a temporary arched frame shell on your truck. So whether you need a cab-high truck cap that screams “space” and “style,” or whether life demands a little more and you need a mid or high-rise cap to get your work done, we’ve got the right cap for your pickup. To mount the drawers l purchased some 20" drawer slides at Home Depot. so evaluate inside of the frame, not just the exterior before making a purchase.) Mine turned out good. 1 year ago Frank refused to do anything to resolve the issue or reduce the price. Answer l am running electrical to both sides of the bed where I'm going to have a little built in night stand with an outlet for a phone charger. Since I plan to make my own door I control the rough opening for that.I've included photos of different tools and materials that I've used on the project. l purposely errored on the side of caution when l cut them in knowing that I could always make them deaper later. I've had 2 pieces in my garage left over from another project for years. That would have been a disaster.We primed all the wood - top, bottom, and sides, and painted them the same way with 2 coats of exterior black porch paint.I ran the wire for the trailer lights through the trailer frame. If you demo it you can save a lot of time, but forget about being able sell the parts. I also sprayed inside of the frame from each open end and from every penetration hole. l've decided to just build my own door. Today I went to the lumber yard to purchase the rest of the interior pre-finished birch paneling. Question The wider gaps, holes, etc will require spray foam. For just about $100 in lumber and an afternoon worth of work, you can build this DIY truck bed camper setup in the transformer style. This is also supposed to be a hobby project that I enjoy.OK, update - My original goal of mid-July 2016 has come and gone. At this point I'll be doing all of my final layout work on the bed and storage areas, and I'll cut and dry fit all of the components.I installed 12"x12" stick down vinyl floor tile to the floor area of the storage compartment. The 1/4 inch plywood is actually 3/16 as you probably know. I took several months off to fish, hunt and spend time on other things since camping season had really come and gone. I used Rust-Oleum Rust Reformer.I re-packed the wheel bearings, that took about 60 - 90 minutes.I put one coat of the rust reformer primer top and bottom on the frame. Stunning. Once I've screwed the plywood in place I'll attach the carpeting and run it over the front 1" bull nose and tack it on the underside. Truck Bed Camper with Storage. In final reparation of standing the walls l used Crack Shot high performance Spackle Paste to fill in any gaps, cracks, deep scratches, holes, etc. l cut them both to 33 1/4" x 77" which gives me a 67 1/2" width. Reply The adhesive is a quick set so be prepared to work fast. I tried it. We taped up the inside paneling around the beam pockets so that when the glue expands it won't be a problem on the finished walls. You built a real nice camper however the foam you used was the exact same material that our first and last motorhome was built from and I really do not recommend that stuf to anyone because it simply falls apart due to heat/cold cycles,the glue used to hold the walls on fails too so good luck and please be carefull. I have my front and back walls all trimmed up and ready to finish the interior side of the walls by cutting and gluing the paneling on. Wish me luck!! It's going to be close on my final wall width as to weather the screws reach or not. But then that’s modern living, I guess. DON'T use a drywall joint compound with wood glue mix. You can demo the trailer or deconstruct it. Using a hot knife for this job is by far the best approach. My reason for making the change to plywood? 19" W x 20" D x 6 1/2" H. l had some luan left over from another project so l used that for the bottom. We used 2 bottles of glue and started with the long drivers side wall. I've decided to build a hard shell camping trailer that will give me the maximum amount of interior room possible and still fit in my garage. Tyler Thompson and Erin Sofinowski built the camper for about $6,000. Great fit inside. New to Instructables... Love your concept.. l used gorilla wood glue and 2" nails to hold it in place while the glue is setting up. That was the restoration God's saying NO SHORT CUTS. l used left over foam board to make the cover. l saw that on a foamie blogg. l then screwed some 2 1/2" drywall screws in around the bottom to snug the wall up to the 2×2" glue track. We put 1 coat of pre stain on and 1 coat of red mahogany stain on. My favorite part is in little type on the third photo in Step 16 where it says "86 More Images." I'm making a pop up camper and decided to do the lower part the way you did yours and then make the roof so light weight with poor mans fiberglass that I can lift it by hand instead of putting a complicated winch system in and have it sit on conduit poles. l also did the same around the wheel wells as well as all 4 corners. It goes on pink while it's wet and it turns white when it's completely dry and ready to be sanded. To install wood blocking to screw into just a bit to begin with damage would be scrap anyway of. 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