DIY WEDGE CAMPER BUILD

After much consideration I decided to pull the trigger and build my own wedge camper. I've owned a 2003 Palomino pop up camper that weighed approximately 900 lbs and it was outstanding on the Dodge Dakota with air lift suspension. However the weight is just not ideal for any rock hopping. The goal of this build was and is complete minimalism and function as well as keeping cost down. I was able to salvage all of the aluminum from my work. My cost for this build I plan to be well under $2000. I just purchased the Alupanel for the skin at a staggering $750. All of the other accessories have been as needed and I will post costs as I continue in this build thread.

 

Cool. I will be following your build.

 

Frame size was originally going to be 55" wide when I designed it in sketch up, however because a queen bed is 60" wide I decided to make it 60". Do not go bigger than this unless you are using a different material than Alupanel or MaxMetal, as they max out at 5x10' sheets and are very hard to find. Purchased a rivet gun from Harbor Freight for $20 and (100) 1/4" dia rivets for $3. As you may tell the cut off pieces of aluminum I got for free were not long enough for the entire length of the bed, so I had to make due and join pieces together.

 

Going to add cross members next and then sand the Al down for paint.

 

Cross members added. Sanding the aluminum with course and fine steel wool in for paint prep.

 

Bottom and top rails for the wedge camper completed. They are a bit flimsy but I imagine once installing the Alupanel skin it wont be an issue.
I framed the top panel to be approx 1/2" larger in every direction than the bottom panel to promote water staying out of the bottom section.
The bottom was framed with out bending any aluminum, the top I wanted to make a stronger connection so I wrapped the al around the corners.
The seal between the two is something I am still considering how to make it water tight. Any tips or ideas would be greatly appreciated!

 

This photo highlights the stop used the helps keep the top and bottom panels aligned

Very happy with the clean look. Top fits right over the bottom, this will be very helpful for water proofing


Inside I used an 1.5"x1.5" x 1/8" thick al angle cut for the corner

 

Oh yeah, definitely on board for this one.

 

Very cool project! What about some heavier duty weather stripping from the Home Depot or other hardware store. I once purchased some 1” wide by 1/4” thick foam weatherstripping that was pretty heavy duty. Self adhesive backing too.

 

This looks rad, following for sure. You've seen:
https://www.tacomaworld.com/threads/how-to-diy-wedge-camper.604686/
Right?

 

@eccracer104 Check this out

 

Thank you Dan! I am taking a HD run today and will take a look. I think my main concern is lining up the weather stripping so it makes a seal when top and bottom come together. I'll keep updating what I decide on.

 

I've poured over Ripcords build and many others! I didnt want to wait 3 months for the 80/20 extrusions, so i went all in with 1x3x1/8" Al angle.
Alupanel is also very hard to find in the 5x10' size. I called 5 different sign stores before finding one that had a vender that had any that wasnt months out.
Are you looking to start a build?

 

Im looking to start a build, so this is very interesting.

I wanna do something like this:


But yours is pretty awesome. Maybe bolt some blocks of lightweight wood in the corners to keep everything square…dunno. Loving the progress.

 

Very excited to follow this. Have read tons of Ripcord style build threads and i like the use of aluminum extrusion but this seems like a very cost effective and light solution. I am just curious in regards to rigidity with the use of rivets vs welding. Though your crossmembers/gussets seem to offer good support.

 

Yea, if you supply the rods and beer im sure you could find someone to throw some weld at it. I think harbor freight has a ac/dc welder for $200 and you could probably do fair enough after 5 ft of practice and youtube.

i learned on a mig with sheet metal and flux core took a whole summer before youtube.

 

This looks great! Stoked to see how it turns out.

 

i built a camper and was super fussy about waterproofing. This is what comes to my mind in your situation. Please dont mind the childish drawing haha

 

Im just gonna assume that this dude made a lot of paper geese as a kid.

 

Hilarious!

Finally found 5x10!

 

Found these bad boys on the zon, pair for 20 bucks ILO 35 each for the legit ones, reviews were pretty good. I decided not to go with the cheapest option I could find (also linked below)

$17 STHang-D 2PCS Compression Latch OEM Replacement Flush Lever Latch Lock for Marine Car Door Hand Lock Adjustable Lever Latches Thickness:1~5mm

https://www.amazon.com/gp/product/B07ZNHFFZ6?ie=UTF8

$20 2 PCS Compression Latch OEM Replacement Southco C2-43-25 Flush Lever Marine Applicable Door Thickness:1~5mm

https://www.amazon.com/Compression-...9efacb3eb2c&pd_rd_wg=nVp75&pd_rd_i=B072JCC7P8

 

Any recommendations on sealing this connection point between Alupanel and Aluminum angle? I'm thinking caulking but still a bit worried about it.

 

Digging the drawing, thank you. I want the waterproofing to be concealed it the top..

 

I would recommend Sikaflex construction sealant for those joints. Usually sold in white and some grey colors at local hardware stores. It's more resistant to fatigue from flexing and should last longer than any normal caulk or silicone.

https://www.lowes.com/pd/Sika-10-1-oz-White-Non-Sag-Construction-Sealant/999977054

For flat roof joints they make a self leveling version similar to dicor self leveling lap sealant too. Very thin/watery to flow but great for sealing roof seams for thru holes for fans/mounts/etc.

 

Super cool! If you haven't already, check out overlandunderbudget on Instagram, he essentially made what you're working on

 

Agreed on the Silkaflex. Also rough those joints up with some 80 grit before you apply.

 

Time to see how good we are with a circular saw.


Not bad


I'm using the same SS hinges that ripcord snagged from the depot.


I also bought some polyhinge after reading about GFC using these, apparently they have been known to tear, so I went with the belt and suspenders with stainless steel hinges underneath.
,

 

At this point I am REALLY questioning his budget if he is still under

 

hahahaha I'd have to agree lol! It doesn't help us regular guys when he's getting things sponsored either

 

Cutting out for the latches aint to bad!