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“Challenges of Building�a Truck Camper”

Bruce from Cape Cod

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Presentation Overview

  • Planning
  • Construction
  • Utilities
  • Ongoing Modifications
  • What We’d Do Differently
  • Statistics

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Feel free to ask questions anytime!

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Why Not Buy One?

  • Already owned a Canyon
  • Factory compact truck campers sleep 3 or 4
  • Required Creature Comforts
    • Usable counter & storage space
    • Heat, hot/cold water, porta-potty, fridge, shower

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  • BUILDING IT WOULD BE FUN!

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Two Major Truck Challenges

  • Space
    • 41” between wheel wells
    • 6’ bed length
  • Weight
    • 1,654 lb usable load including people

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Space: Floor Plan

Challenges:

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First Day: Minimal Space Dinette?

- Drew Plans on Garage Floor

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Last Day:

- How to Mount Table?

- “Lap joint” slide in

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Challenge: Size & Weight Planning

Before

Drawing

Plans

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The Floor� was the �First Part!

box width 39.5”

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Presentation Overview

  • Planning
  • Construction: Tools & Fabrication
  • Ongoing Modifications
  • What We’d Do Differently
  • Travel Stats

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Tools

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2 Saws

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Kreg Pocket Screw Kit

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�Gas�Tubing �Flare �Tool

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Wiring – Solder & Shrink Wrap

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Construction Sequence

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  1. Box & Wings. . .�

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. . . Made of 10 Parts. . .

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. . .Insulated. . .

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… & Covered!

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2. Front Wall

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3. Left Side Wall …

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..& Right Side Wall!

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4. Back Wall

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5. Attach Walls. . .

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…Then Bed

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6. Add Ceiling & Roof Supports

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7. Paint Interior, �8. Add Cabinets, Utilities & Wiring…

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…More Cabinets, Water, & Gas. . .

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…Electrical System

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9. Check the Fit

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10. Insulate Walls & Ceiling

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11. Staple Siding

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12. Add Sheathing & Rubber Roof. . .

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…Windows and Door

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13. Interior Trim: Cabinet Doors�14. Floor, Curtains, Cushions by Pam �

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DONE!!

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Truck Modifications

Battery Isolator

Connections

80 PSI = Factory Level

Internal Tie Downs

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Camper Mods Since 2010

  • Shelves in most cabinets
  • Bath towel racks
  • Cabover drag reducer (ineffective!)
  • Lighter socket for USB Charger
  • Hanging net for lightweight storage
  • Compact folding chairs
  • 12V HD Television & antenna
  • Porch lights
  • Hooks for inside clothes line
  • 3-way ‘fridge replaced by 12V freezer/fridge
  • Truck: Replace battery isolator with voltage sensitive relay - Simpler & more reliable

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The Turkey Accident - 2013

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What We’d Do Differently

  1. Put Hookups on the Correct Side
    • OOOOPPPSSSS!
    • ​
  2. Reduce Aerodynamic Drag
    • More slant/rounding of cabover bed and rear corners

3. Roof rafters with a convex top

    • Shed rain & eliminate puddling

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NFPA 1192 Compliance -

Checked it out in 2017

  • Changes to Comply:
    • Fire Extinguisher Location
    • Potable Water Warning Label
  • Non-Compliant:
    • Nylon vs. Copper clamps on Tubing
    • Location of Utilities to left side
    • Size of gray water drain pipe

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Statistics

  • Camper:
    • Interior Height: 6’1” -Interior Width: 6’3”
    • Overall Length 10’6” -Square feet: 65
    • Weight: ~1,135 lbs -Water: 14 Gallons White & Gray
    • Average 18 mpg -Average Weight: GVW + 350 lbs
    • Electric: 120V/20A with12V/45A supply & 650Ah Marine Battery

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  • Travel:
    • All of the lower 48 states + Canadian Maritimes
    • 53,000 total miles as of September, 2019
      • longest trip was 9,500 miles
    • Dry camping 3-4 day max (water constrained)
    • Over 6 months of living in the camper

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Questions?