How To Make A Crank Handle For Your Pop-Up Camper

Pop-up camper crank handles are available for purchase online. They are typically made of iron and plastic, with a rotatable plastic handle. The length of the handle varies, with options ranging from 9 inches to 12 inches. The handles are designed to fit specific models of pop-up campers, including Coleman, Fleetwood, Starcraft, Flagstaff, Rockwood, Palomino, Dutchmen, Skamper, and Jayco. The price of these handles ranges from $14.99 to $43.99. It is also possible to find replacement parts and repair kits for pop-up camper crank handles.

Materials for a homemade crank handle

A crank handle is used to raise and lower the roof of a pop-up camper and will also work the jacks on most units. The handle grip spins freely, and the T-slot end fits securely into the crank. The most common materials for a crank handle for a pop-up camper are iron and plastic.

The length of the crank handle will depend on the manufacturer of the camper. For example, the Coleman CLCRNK/Fleetwood Pop-Up/Tent Camper Crank Handle is 12 inches long, while the Goshen Crank Handle for Starcraft/Flagstaff/Rockwood/Palomino/Dutchmen/Skamper Pop-Up Campers is 9 inches long.

The diameter of the end of the crank handle is also important to ensure a proper fit. The Coleman and Fleetwood crank handle has an end diameter of 7/8 of an inch.

When making a homemade crank handle for a pop-up camper, it is important to consider the length and diameter of the handle, as well as the materials used to ensure a proper fit and functionality.

Some other materials that could be used for a homemade crank handle include:

• Wood: A wooden handle could provide a comfortable grip and be shaped to fit the user's hand.
• Aluminium: Aluminium is a strong and lightweight material that could be used to create a durable crank handle.
• Steel: Steel is a strong and durable material that could be used to create a crank handle that can withstand heavy use.

Design and functionality

The design of a crank handle for a pop-up camper is crucial to ensure smooth and efficient operation. The handle should be designed to fit securely into the crank mechanism, allowing for easy rotation and providing enough torque to raise and lower the roof.

One of the key design aspects is the T-slot end, which needs to fit securely into the crank. This T-slot should have a sufficient reach to engage with the pin in the crank, typically around 7-1/2 inches. The diameter of the crank handle's end should also match the size of the crank's pin, usually measuring around 7/8 of an inch.

The overall length of the crank handle plays a role in the functionality. A longer handle provides more leverage and makes it easier to turn, while a shorter handle might require more effort but could be more compact and portable. The handle grip should be designed to spin freely, allowing for smooth operation without causing discomfort or burning the user's hand during cranking.

Materials used for the crank handle are important for durability and strength. Metal crank handles, often made from iron, are commonly used and provide the necessary strength to withstand the pressure of raising and lowering the pop-up camper roof. PVC piping has also been used as a DIY alternative, but it may not be as reliable under high pressure.

Additionally, the design of the crank handle should consider any additional features that enhance its functionality. For example, a sleeve or cover for the handle can prevent the user's hand from burning during operation. Cordless drill crank adapters are also available, providing an alternative way to operate the crank handle with a power tool.

In summary, the design and functionality of a homemade crank handle for a pop-up camper should focus on secure fitment, ease of rotation, sufficient torque, and user comfort. The materials used should be strong and durable, with metal being a common choice for reliability. Additional features, such as sleeves or cordless drill adapters, can further enhance the functionality of the crank handle.

Compatibility with different camper models

Firstly, it's important to identify the make and model of your pop-up camper. Different brands like Coleman, Fleetwood, Starcraft, Flagstaff, Rockwood, Palomino, Dutchmen, Skamper, and Jayco have specific crank handle designs that may not be interchangeable. For example, the Coleman CLCRNK/Fleetwood crank handle is designed specifically for Coleman and Fleetwood pop-up campers and may not work with other models.

Secondly, the age of your camper also plays a role in compatibility. Some crank handles are designed for older models, such as the Starcraft 1994 and Older Pop-Up Tent Camper Replacement Crank Handle, which is compatible with Starcraft campers from 1994 and prior. Similarly, the ROCKWOOD CRANK 1993 - Prior Pop-Up Tent Camper Replacement Crank Handle is designed for Rockwood campers from 1993 and earlier.

Thirdly, the type of drive system your camper uses is crucial. Campers with drive hub extension tubes, commonly found on units produced after the 1990s, require a different crank handle than those with a drive shaft. The new-style Coleman crank handle, for example, works with drive hub extension tubes but may not be compatible with a drive shaft.

Additionally, the length and dimensions of the crank handle must match your camper's specifications. The Coleman and Fleetwood original crank handle, for example, measures 12 inches in total length, while the new-style handle is 11-3/4 inches. The T-slot end reach and the diameter of the crank handle end also vary between models.

Lastly, some handles are designed for specific camper models. For instance, the L & W Crank - Older Jayco/Viking/Coachmen Pop-Up/Tent Camper Crank Handle is designed for older Jayco, Viking, and Coachmen campers, while the Canimex Crank Handle is compatible with Coachmen and Viking campers from 2013 to 2018.

It's always advisable to consult product specifications, user manuals, and compatibility charts to ensure the correct crank handle for your pop-up camper model.

Pros and cons of a homemade handle

Pros and Cons of a Homemade Crank Handle for a Pop-Up Camper

A homemade crank handle for a pop-up camper can be a great, cost-effective solution in a pinch, but it does come with some potential drawbacks. Here are some pros and cons to consider:

Pros:

• Cost savings: Creating your own crank handle can save you money, especially if you already have the necessary materials and tools.
• Quick solution: If you need a replacement handle in a hurry and don't have time to wait for delivery or go out to purchase one, making your own can be a faster option.
• Customization: You can customize the design to your specific needs and preferences, ensuring a perfect fit for your pop-up camper.
• Creative satisfaction: For those who enjoy DIY projects, there is a sense of satisfaction and accomplishment in creating your own solution.

Cons:

• Durability: The durability of a homemade crank handle may be questionable, especially if made from materials like PVC piping. Metal is likely to be more reliable but may require welding or other specialized equipment.
• Safety: A handle made from weaker materials may fail under pressure, potentially causing injury or further damage to your camper.
• Time and effort: Constructing your own crank handle takes time and effort, and there is a learning curve involved in getting it right.
• Lack of standardization: A custom-made handle may not conform to standard sizes, which could make it difficult to find replacement parts or make adjustments in the future.
• Resale value: If you plan to sell your pop-up camper in the future, a non-standard crank handle could be a potential drawback for buyers.

In conclusion, while a homemade crank handle for a pop-up camper can be a creative and cost-effective solution, it's important to carefully consider the potential drawbacks, especially those related to safety and durability.

Step-by-step guide to making a crank handle

Step 1: Gather Materials and Tools

You will need the following materials and tools to make a crank handle for a pop-up camper:

• Durable construction material such as metal or plastic
• Measuring tape
• Saw or cutting tool
• Drill
• Sandpaper or a file
• Safety gear, including gloves and eye protection

Step 2: Measure and Cut the Material

Use the measuring tape to measure out the required length for your crank handle, marking the material with a pen or pencil. The standard length for a pop-up camper crank handle is 12 inches, but you may need to adjust this based on your specific camper model. Once marked, use a saw or cutting tool to carefully cut the material to the desired length.

Step 3: Drill the Hole

At one end of the crank handle, use the drill to create a hole that will fit securely into the camper's crank mechanism. The standard size for this hole is 7/8 of an inch in diameter, but again, refer to your camper's specifications to ensure an accurate fit. Drill slowly and carefully to avoid splintering or cracking the material.

Step 4: Smooth and Sand the Handle

To ensure a comfortable and safe grip, use sandpaper or a file to smooth out any rough edges on the handle. Pay particular attention to the end of the handle that will be gripped, as well as any areas where the material was cut or drilled.

Step 5: Test the Fit

Once you've finished shaping and smoothing the crank handle, test its fit in the camper's crank mechanism. It should slide in securely but not too tightly, and it should be able to rotate freely. If necessary, make minor adjustments by sanding or filing the handle further.

Step 6: Finish and Protect the Handle

Finally, you may want to apply a finish or coating to protect the crank handle from the elements and prevent rust or corrosion. This could be a paint, varnish, or other sealant suitable for the material you have used. Follow the instructions for your chosen product, and allow the handle to dry completely before use.

Frequently asked questions