Hauling Fiberglass Camper Shells Upside Down: Safe Or Not?

can a fiberglass camper shell be hauled upside down

Fiberglass camper shells are a great way to store your gear and provide protection from the elements. They can even be used as a sleeping space. However, they are not designed to hold much weight, and adding a rooftop tent can be dangerous. The average fiberglass camper shell cannot support the weight of a rooftop tent and a person sleeping in it. The weight will cause the camper shell to collapse. To avoid this, you can reinforce your fiberglass camper shell by adding an internal frame or using heavy-duty materials such as aluminum or steel.

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Weight-bearing capacity of fiberglass camper shells

The weight-bearing capacity of a fiberglass camper shell depends on various factors, including its design, dimensions, and reinforcement. While fiberglass is known for its strength and durability, standard camper shells may not be able to support the weight of a rooftop tent and a person sleeping in it.

Most fiberglass camper shells have a weight capacity ranging from 150 lbs to 650 lbs. However, it's important to note that these values may represent static weight capacity, which is higher than the dynamic weight capacity for driving. The dynamic weight capacity is the amount of weight the camper shell can safely support while the vehicle is in motion.

To increase the weight-bearing capacity of a fiberglass camper shell, internal supports or reinforcements are necessary. Some camper shells are designed with aluminum or steel skeletons, significantly increasing their weight capacity. For example, the A.R.E. camper shell is made of aluminum and is rated to support 550 lbs. Similarly, the RSi SmartCap, made of heavy-duty aluminum and steel, is capable of bearing heavier loads.

When considering adding a rooftop tent to a fiberglass camper shell, it is crucial to take into account the weight of the tent, the number of people sleeping in it, and the weight distribution. A typical rooftop tent weighs around 225 lbs, and each person can add an additional 200 lbs or more. Therefore, a safe weight capacity for the camper shell should exceed the total expected load.

In summary, the weight-bearing capacity of a fiberglass camper shell varies depending on its design and reinforcement. While standard shells may not support a rooftop tent, those with internal supports or made of heavy-duty materials can safely bear heavier loads. It is essential to research the weight capacity and restrictions of both the camper shell and the rooftop tent before making a purchase decision.

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Reinforcing a fiberglass camper shell

Using Internal Supports:

  • One method is to add internal supports or a frame to bear the load. This can be done using materials such as billet aluminium, steel, or square tubing. These supports are connected to the bed rails of the truck through the fiberglass shell.
  • Another option is to use climbing anchors or large washers on the inside of the shell to distribute the stress when mounting racks or other equipment.

Reinforcing with Additional Layers:

  • You can reinforce the roof of the camper shell by adding another layer of fiberglass and resin to the inside. This will strengthen the roof and allow you to mount equipment without the need for an external rack.
  • Alternatively, you can use a combination of fiberglass and plywood. Cut boards to fit the length of the camper shell and epoxy them in place. Then, add additional layers of fiberglass and epoxy over the boards, creating a stronger bond.

Using Adhesives and Sealants:

  • When mounting the camper shell to your truck, use an adhesive insulation tape along the bottom of the shell, excluding the rear hatch, to ensure a secure fit and prevent leaks.
  • For additional reinforcement, you can use aluminium hardware clamps to secure the camper shell to the truck bed rails and drill holes to bolt the shell in place.

Choosing the Right Camper Shell:

  • If you haven't purchased a camper shell yet, consider choosing one designed to support excess weight. Companies like A.R.E. and Go Fast Campers (G.F.C.) offer camper shells made of aluminium or composite materials that can handle heavier loads.
  • Keep in mind the weight of your rooftop tent and the number of people sleeping in it. The average fiberglass camper shell may not be able to support this weight, so opting for a heavier-duty option could be a safer choice.

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Sealing a fiberglass camper shell

Sealing a fibreglass camper shell is an important step in ensuring your safety and comfort when camping. Here is a comprehensive guide to help you seal your fibreglass camper shell effectively:

Step 1: Prepare the Camper Shell

Before you begin sealing, it is essential to clean the camper shell thoroughly. This includes removing any dirt, dust, or debris that may be present, especially if it is an old shell. If there is mould or stains, gently pressure wash the shell and allow it to dry completely. If there is loose fibreglass or splintering, you may need to sand the surface to create a smoother base for sealing. Ensure you wear the appropriate protective gear, including a respirator and goggles, when sanding fibreglass to avoid inhaling the dust.

Step 2: Choose the Right Sealant

There are various options available for sealing a fibreglass camper shell. You can choose from epoxy resin, gel coat, marine paint, or a specialised product like Lizard Skin, which offers insulating and sound-deadening coatings. Epoxy resin is a popular choice and can be applied with a foam roller for an even finish. Alternatively, you may opt for a spray-on or roll-on truck bed liner for added protection.

Step 3: Apply the Sealant

Once you have selected your sealant, carefully read and follow the instructions provided by the manufacturer. In most cases, you will need to flip the camper shell upside down and place it on a suitable work surface, such as a blanket or old carpet. Ensure the shell is stable and well-supported. Prepare the sealant as instructed, and then apply it evenly to the interior of the shell. Use a foam roller or brush to achieve the desired texture and finish. Allow the sealant to dry thoroughly according to the manufacturer's guidelines.

Step 4: Optional Finishing Touches

After sealing, you may wish to add additional layers of protection or insulation. One popular option is to carpet the interior of the camper shell. This can be done using spray adhesive or heavy-duty adhesive spray, such as 3M 90, to attach the carpet securely. Ensure the carpet is cut to fit the contours of the shell, providing a snug and comfortable finish.

Step 5: Reinstall the Camper Shell

Once the sealant and any optional finishes have dried completely, you can reinstall the camper shell onto your vehicle. Follow the manufacturer's instructions or seek guidance from a professional if you are unsure about the installation process. Ensure all connections are secure and that there are no leaks or gaps that could compromise the integrity of the seal.

By following these steps, you can effectively seal your fibreglass camper shell, creating a safe and comfortable environment for your camping adventures. Remember to take your time, work in a well-ventilated area, and always prioritise your safety when handling chemicals and equipment.

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Building a DIY fiberglass camper shell

If you're planning an extended overlanding trip, a camper shell is a great way to store your gear and protect it from the elements. Building a DIY fiberglass camper shell can be a rewarding project, allowing you to convert your truck into a comfortable sleeping space without the hassle of setting up a tent. Here's a comprehensive guide to help you build your own lightweight and functional DIY fiberglass camper shell.

Planning and Preparation:

Before starting, ensure you have a suitable working space, especially if you live in a city. You may need access to a garage or a similar space. Gather all the necessary tools and supplies, which can be purchased online or from local hardware stores. Here's a list of what you'll need:

  • Industrial-length Velcro
  • Mexican serape blanket
  • Fiberglass screening
  • Neoprene stripping tape
  • Portable power station
  • 15ft charging cable
  • Undercover swing case
  • Nuts, bolts, washers
  • Fabric scissors (heavy-duty)
  • Small hand saw or Dremel tool
  • PVC pipes and connectors
  • Adhesive insulation tape
  • Aluminum hardware clamps

Remember that patience is essential for any DIY project. Stay level-headed, and don't get discouraged by mistakes. Enjoy the process and feel free to seek additional guidance online through Google, YouTube, or Amazon.

Building the Truck Cap:

Start by taking measurements of your truck bed's interior length and width. Cut PVC pipes accordingly:

  • Cut four pieces with the same length as the bed.
  • Cut four pieces with the same width as the bed.

Nail or glue the length pieces together to form a square. Repeat the process without one width piece to create another square.

Connect these two squares using four short PVC pieces to form a cube-like structure, matching the length of your truck bed. This cube will have a missing lower piece, allowing space for the tailgate. Let the frame dry for 10-20 minutes.

Make holes for windows and install fiberglass screening to create functional windows. Ensure proper sealing to prevent leaks during rainy weather.

Applying Adhesives and Mounting the Truck Cap:

Spread a blanket on the ground, larger than your truck. With assistance, flip the truck cap upside down and place it gently on the blanket. Apply adhesive insulation tape around the entire bottom of the truck bed, except for the rear hatch, to ensure the tailgate can open and close freely.

Carefully mount the truck cap onto the truck bed, ensuring it sits evenly on both sides.

Securing the Truck Cap and Wiring:

Secure the truck cap by applying two aluminum hardware clamps against the truck bed cap and rail. Drill holes to fit the truck cap onto the rails using bolts. Drill an additional small hole for the wiring of the tail light assembly.

Locate the brake light wiring and connect the wires to the high-mount brake lights. If you encounter any difficulties, refer to online resources or YouTube for guidance on wiring tail lights for truck caps.

With these steps completed, you now have your very own DIY fiberglass camper shell! Don't be discouraged if it doesn't turn out perfectly the first time. DIY projects often come with challenges, and you can always refer to online resources for additional ideas and improvements.

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Fixing a fiberglass camper shell

Fixing a fibreglass camper shell can be a challenging task, but with the right tools, knowledge, and patience, it is certainly achievable. Here is a comprehensive guide to help you through the process:

Assess the Damage

Before beginning any repairs, it is important to assess the extent of the damage to your camper shell. Look for cracks, holes, or any other structural issues that need to be addressed. Take measurements of the affected areas to determine the amount of materials you will need for the repairs.

Gather the Necessary Tools and Materials

To fix your fibreglass camper shell, you will need a range of tools and materials, including:

  • Fabric scissors (heavy-duty)
  • A small hand saw or a Dremel tool
  • Velcro of industrial length
  • A Mexican serape blanket
  • Fibreglass screening
  • Neoprene stripping tape
  • Adhesive insulation tape
  • Aluminium hardware clamps
  • Drill
  • Wiring and connectors for brake lights
  • Fibreglass resin and matting (for larger repairs)
  • Sandpaper (for smoothing repaired areas)

Choose a Suitable Work Location

Select a spacious and well-ventilated area to work on your camper shell. If you live in a city, you may have access to a garage or workshop. Alternatively, you can set up a temporary workspace with a tarp or drop cloth to catch any debris or spills.

Prepare the Surface

Before beginning any repairs, clean the surface of the camper shell to ensure that it is free of dirt, grease, or debris. Use a mild detergent or fibreglass cleaner and a soft cloth to gently wipe down the area. If there are any loose pieces of fibreglass or debris around the damaged area, carefully remove them using a hand saw or Dremel tool.

Make Necessary Repairs

The specific repair process will depend on the type of damage your camper shell has sustained. For small cracks or holes, you can use a fibreglass repair kit, following the manufacturer's instructions. Larger holes or structural repairs may require more extensive work:

  • Cut away the damaged area: Use a saw or Dremel tool to carefully cut away the damaged fibreglass, creating a clean and straight edge around the hole.
  • Prepare the fibreglass patch: Measure the size of the hole and cut a piece of fibreglass matting to match. The patch should overlap the hole by at least 1 inch on all sides.
  • Apply fibreglass resin: Mix the resin according to the manufacturer's instructions. Using a brush or roller, apply a thin layer of resin to the area around the hole. Then, place the fibreglass patch over the hole and saturate it with resin. Smooth out any air bubbles or creases.
  • Allow the resin to cure: Follow the curing instructions provided by the manufacturer. The curing process may take several hours or even days, depending on the product used.
  • Sand and smooth the repaired area: Once the resin has cured, use sandpaper to gently sand the repaired area, blending it with the surrounding surface. Work in the direction of the fibreglass strands to create a smooth and even finish.

Reinstall the Camper Shell

Once your repairs are complete and the resin has fully cured, you can reinstall the camper shell onto your vehicle. Carefully align the shell with the truck bed and secure it using the appropriate clamps or fasteners. Ensure that all connections are tight and secure before hitting the road.

Finishing Touches

Depending on the extent of the repairs, you may need to apply a fresh coat of paint to match the original colour of your camper shell. This will help protect the fibreglass and improve the overall appearance. Follow the paint manufacturer's instructions for proper application and curing.

Remember, when working with fibreglass and resins, it is important to prioritise your safety. Work in a well-ventilated area, wear protective gear (gloves, eye protection, respirator), and always read and follow the instructions provided by the manufacturers of the products you are using.

Frequently asked questions

Yes, it is possible to haul a fiberglass camper shell upside down. However, it is not recommended to do so for an extended period as it may cause damage to the shell. Hauling it upside down can put stress on the structure and cause cracks or other issues.

Hauling a fiberglass camper shell upside down can exert stress on the shell, especially if it is loaded with gear or other heavy items. This can lead to cracks, structural damage, or even catastrophic failure.

To reinforce a fiberglass camper shell for hauling upside down, you can consider adding an internal frame, using climbing anchors or large fender washers, or reinforcing the roof with additional layers of fiberglass and resin. These methods can help distribute the weight more evenly and reduce the risk of damage.

Instead of hauling the camper shell upside down, you can explore other options such as using a different material like heavy-duty aluminum or steel, or investing in a ready-made camper shell designed to handle excess weight, like the A.R.E. or Go Fast Campers (G.F.C.) models. These alternatives can provide a stronger and more durable solution for transporting your camper shell.

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