Design and Construction of a Custom Built Slide-In Cabover Truck Camper
Monday, August 19, 2013
Weight of the Camper after it was all said and done.
I do know that the entire collection of sheetgoods (Nida-Core) weigh in at 32 pounds per and I had 10, minus the small segments leftover that were thrown away. Would have been 11 but ended up settling for a piece of 3/4" plywood- epoxied saturated and painted- for the backwall.
1) So the weight of 10 sheets of Nida Core = 320 pounds
2) one piece of 3/4" plywood = 30-45 pounds
3) must have at least 7 gallons of resin = 80-100 pounds
4) must have at least 40-50 pounds of cloth
(320) + (37.5) + (90) + (45) = 492
and my guess would have been around 600-700...so somewhere in the ballpark between 500-700 pounds
just right for the 1/2 ton with air bag helper springs...no issues in transit
I have never had a chance just yet, to actually obtain my truck total weight on a set of scales since the camper has been added so that's the best I have to offer currently.
-chris
Sunday, August 18, 2013
The shower water heater and choices
I had seen an 'in-use water heater shower head' years ago and began a search for a reputable supplier. I ended up landing on the Marey Heater Corporation site, this firm is located in Peurto Rico and offers the 120 VAC in-use water heater, shower head. I was a bit concerned having such an arrangement- wet environment, powered unit in the shower- but there appears to be safeguards (insulated housing). I plan on installing a ground fault circuit interrupter (GFCI) on this circuit. One should never have any type of electrical install that serves a wet area (sink, countertop, exterior app) without one. Matter of factly it is a National Electrical Code mandate across US....well yeah- 'national- US..duh!'--lol. A 30A GFCI circuit breaker will suffice.
I understand these units are commonly used all throughout Peurto Rico, various parts of Mexico and perhaps other portions of Central America within their dwellings and commercial buildings.
My plumbing was certainly not the neatest install, but functional. I have a switch for the shower head and another switch for the water pump. I can turn the power off to the shower head before I disengage the pump, thus preventing a dry element incident.
The piece of angle the shower head is mounted to is for rigidity while in transit because the shower head is forward heavy. The surface mounted plumbing allows me to remove the unit should it ever need replacing. Was not enough room in my wall studs for the fitting arrangement and it was O'dark-30 when I was working on this, no stores open and I needed this baby in. Anyway it's not a photo booth, just an area to wash after a day of field research.
Interior camper snapshots...still a work in progress
after plumbing and electrical is complete will complete cabinetry underneath sink |
As you can see in the picture below there is an electrical junction box mounted between the wall studs. This box is for the 120 volt service supplying the instantaneous hot water showerhead. Above that is an 'out of the box' low voltage application (switch) which runs the 12 VDC waterpump. This allows me to turn off the waterheater electrical supply just prior to turning off the pump to ensure I do not have a dry element and ruin the showerhead.
A peek underneath the sink shows where the incoming water line will be connected and the sink drain/vent.
if you missed the shower rough-in, check that out here
Wednesday, June 26, 2013
Truck Air Springs (Air Bags) Install - Air Lift Ride Control
I was a bit concerned with having sufficient wheel clearance between the back sides of my tires and the air bags when inflated after reading some of the reviews about the bags that are posted online. I believe most of those individuals have larger than factory type, off road tires. Although, I have a hybridized off road tire on my truck they are not as wide as some of the one's specifically geared towards offroading are. I was able to install the bags on my truck and even after inflating them still have ample space between the two.
I spent the better part of 6-8 hours one evening to take both rear truck tires off and to install the springs. Ended up calling a good friend so that I could utilize his concrete driveway to do so. Was not about to execute this feat on grass lawn. The proper mounting of the brackets come with a handy dandy little device in the kit, that allow you to properly align the two bracket halves alongside the chassis where they are to be mounted, so you can obtain location specific marks for drilling.
Then I had to drill some holes in the chassis...newly purchased, sharp HSS bit made this go smoothly.
Overall, the install was not difficult. Routed a little bit plastic air hose to the rear of vehicle (supplied in kit) where I mounted my valve stems in the bumper near the registration plate mounting area and I was in business. It only takes a small bicycle tire handpump to maintain these bags. I am able to keep them taut with only minimal air pressure. I am impressed with the ease of operation in inflating these...they really work well.
I have not had any issues with loss of air from the bags and they have been on over a year now.
installation location of my air bag valve stems |
Sunday, June 23, 2013
Giving Truck Grille A Paint Overhaul
I used the Petit EasyPoxy Marine Grade Topside Paint from Jamestown Distributors, cut a little with thinner and sprayed through a cheap high volume-low pressure, gravity fed sprayer. The paint job turned out, well almost terrific. The quality of the paint had everything to do with it, I'm certain. Self leveled and cured flat, smooth and glossy.
You can see after sanding just how bad the grill was, those grayish areas is the underlying color composition of the plastic where the paint had depleted.
Camper Tie Down Attachment Point UPDATE
The eyebolts purchased from McMaster are serving me well. After several months, a check of all the attachment points are seemingly doing fine.
The HappiJac camper tie downs mounted on the truck cab are doing well although they are digging into the truck bed some, thus cracking the paint job and deforming the metal ever so slightly. The deformation is minor at this point. I did not install a torsion bar between the bed mounted tie downs. Being my truck is an older model, I'm not overly concerned. However, if I had a newer model truck I suppose installing the torsion bar in conjunction with the plates might have been a good idea. The torsion bar is supposed to prevent that 'digging in' from occurring. Mind you...'my camper is even lighter than all commercial units', so I would certainly use the torsion bar tie-in if I were carrying one of those manufactured units in my truck bed.
Those Stainless Steel HappiJac Turnbuckles are everything individuals claimed them to be and a little more. They are extra durabable and have not given me any problems, they stay tight and the inner springs work as the manufacturer claimed. You can occasionally hear the spring as it is being compressed and relaxed, in select topographies. No bother to me...means it working. Load your back and you just might croak every now and again as well 😂
Months of driving and no movement, the reinforced fiberglass area is holding up as planned. To see the structural fiberglass mixture recipe which was used to reinforce this region for the bolt-throughs. The pockets were cut and filled, wrapped in 7-8 ounce cloth, layered with 1708 biaxial cloth on top (both on exterior and interior), both interior and exterior recieved a little more lamination as corners of panels were lain (as seen in photo above)...you can see the wrap. Eyebolts protrude through a 5/16" thick plate on the interior, another 1/4" thick structure washer and possess two nuts.
Saturday, June 22, 2013
Camper Brake / Turn / Clearance Lights...the thoughts concerning laws and the install
You can see that portion of the electrical rough-in here.
It seemed that some of the manufactured units had upper brake light strips in combination with another pair of lights but most did not. My original plans were to have a 2.5 foot strip centered at the top in conjunction with the these 6" round lights. I had even purchased the strip but after the door was installed and the "much needed" rain gutter....something had to give. --> it was the light.
I considered height of install in respect to the 'seated approaching motorist' and wanted them in the plane of sight. These lights are about the same height above ground as the cab brake lights found on all modern pickups and I mounted them just above the vertical plane of my truck lights.
The closer proximity of the light arrangements are far enough apart to be seen as separate at 200-300' but close enough to grab one's attention.
Smittybilt Beaver Tail Step purchased for ease of access
The step weighs a hefty amount as it is all solid metal, no hollow stuff here....just solid metal. Its designed to serve a two fold purpose; a step and an attachment point for vehicle retrievals. Used extensively with those sporting offroaders that need to pull one another out of tight spots and continue onward.
When I say it is hefty and durable, they are understatements...this is a great step folks, really it is. One of those few items that you buy 'once' and it stays intact the remainder of your days. Heck, may even end up on your child's vehicle. They are just that tough. After dealing with the vast array of cheaply designed product on the market today, I must say "I was overly impressed."
Rain Gutter Install Over Door
What seemingly appeared to be a 20-30 minute install turned into a much lengthier one.
revealing the tight clearance above door that I desired |
Monday, April 8, 2013
Design and building of Entrance Door
I took a piece of 3/4" good grade plywood and coated the exterior side really well with 2-3 coats of thin set epoxy which cured a waterproof exterior shell on the sheet. Placed a piece of Fiberglass Reinforced Plastic (FRP) on the exterior of the door. Then made my sealing flanges for the door out of 4" wide fiberglass cloth, that after cure, would be mounted to the outward edge of my door. It worked fairly well. Not the 'most professional looking and certainly not the most aesthetically pleasing' one you have ever seen but it does the job for now.
Thin fiberboard strips cut to appropriate size and wrapped in wax paper to allow me to drape wet fiberglass cloth over the ledges. The idea was that the wax paper would prevent the polyester resin from bonding to the fiberboard and the 1/4" variation in height would create an offset in the cloth thereby creating a 1/4" area to accept weatherstripping so door would shut tight and seal out rain.
Mounting piano hinge and outward edge flanges.
Roll out caulk placed upon hinge line and then hinge fastened.
Interior Electrical System Rough-In
This part of the build was just not uploaded within the appropriate timeframe, that's all. little behind guys!
The interior work came at a time when I was extremely busy with other business ventures. Lots of the construction occurred within crunches 'for time' thus I simply snapped away with the photos and did not have the time to upload and blog during that busy time. So here we are now!
As you recall from the earlier phases of construction, the entire camper is Nida Core honeycomb panels except for the rear wall. (the reason why? i chose wood)
I insulated the rear wall with residential construction foam approximately 1" thick which will be wrapped with some form of paneling on the interior.
Placed horizontal strips of wooden reinforcement in this region where one's back would rest when sitting on the bench, to prevent bowing and damage to the thin wall paneling.
Insulation going up in wall region where shower stall will be installed, notice the sloped seat in this region. The seat was sloped to allow for water drainage when taking showers.
Insulation in place in door before interior panel side was installed. Also can see some of the incipient stages of inlet power installation going on in the background.
Monday, March 25, 2013
12 volt DC System and Onboard Battery Recharge System
I wanted a 12 VDC system for the camper that could be recharged and 'topped off' as I was in transit. I not only wanted to recharge the onboard camper battery with the truck alternator but also wanted to be able to start my truck with this battery, should my truck camper ever be found dead. The latter of which meant a significant wire guage would be needed.
Well as you know....copper is a prized possession. I needed at least a #2 gauge for the potential 200 amp starter draw and the wire needed to be multi-stranded so it would be flexible. Purchased a 20 foot set of #2 AWG heavy duty jumper cables and chopped off the gator clips. The extra fine strands will allow for the ease of routing the cable on the truck frame.
Made very strong connections..Impressed!
A #12 gauge wire was run alongside which was 'fed' from camper battery, serving a switch in cab that I can use to energize the coil of the battery isolator located underneath the hood.
I mounted a Stinger, 200 amp water-tight battery isolator in the engine compartment. I installed a 200 amp ANL fuse and fuseblock to protect the length of wire and ultimately the camper battery from ground faults and short circuits or from overloads if using to start 'third party' vehicles.
The shorter leads used in this connection were just battery leads purchased from a local automotive store. The isolator is controlled from switch in cab fed from camper battery.
The longer bolt was purchased for use on the positive side of the battery, to accommodate the two, stacked OEM cable terminals; the install was painless. As far as the extension portion goes, that section is plenty long as well...have room for future use built-in.
Cable was routed through LB and then into the battery compartment box. Used duct seal here also in order to prevent noxious vapors from entering camper. (See construction of battery compartment box)
To see the creation of the battery compartment box visit here