Building A Cabover Camper: A Step-By-Step Guide

how to build a cabover camper

Building a cabover camper is a complex but rewarding project. It involves designing a layout, constructing a frame, installing electrical and plumbing systems, and finishing the interior. The process requires careful planning, creativity, and a range of skills and tools. The result is a custom-built camper that meets specific needs and preferences, offering a unique camping experience with features such as standing room, storage, and electrical appliances.

Characteristics Values
Purpose Camping, sleeping space, guest/hangout space
Cost $454-$1500
Weight 150-1000 lbs
Materials Wood, steel, aluminium, fabric, glue, screws, nails, electrical parts, fiberglass, plastic, solar panels, etc.
Tools Hammer drill, wrench, dremel tool, saw, cutting scissors, etc.
Time 2-3 weeks
Features Bed, cabinets, electricals, windows, doors, storage, etc.

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Choosing the right materials

Frame Materials

The frame forms the structural backbone of your camper, so choosing a sturdy and durable material is crucial. While lumber, such as 2x2 or 2x4 pine, is a common choice for DIY campers due to its relatively low cost, it may not provide the necessary strength for larger or heavier builds. Aluminium or steel tubing can be excellent alternatives, offering lightweight yet robust options. They are more expensive and require different tools and skills to work with, but they can provide a longer-lasting and safer structure.

Wall and Ceiling Materials

For the walls and ceiling of your camper, consider using plywood, a versatile and affordable option. The thickness of the plywood can vary depending on the application. For example, you may use 1/8" or 1/4" plywood for interior walls and cabinets, while opting for 3/4" plywood for the floor to support body weight. Ensure the plywood is glued and fastened securely to the frame. Additionally, consider insulating the walls with foam to regulate the temperature inside your camper.

Exterior Protection

Protecting the exterior of your camper from the elements is essential. One popular method is to use a fabric and paint combination, often referred to as "Poor Man's Fiberglass." This involves covering the plywood with fabric (such as canvas or bedsheets) and then applying multiple coats of paint. This method is lightweight, durable, and waterproof. Alternatively, you can use fiberglass cloth and epoxy resin for a more traditional approach, providing a smooth and sturdy finish.

Windows and Doors

Windows and doors are essential components of your camper, providing ventilation, natural light, and access. Consider using fixed glass for the side windows, as they are more affordable and easier to install. For the entry door, you may opt for a full-size door or a smaller hatch, depending on your design and space constraints. Ensure that all openings are properly sealed to prevent leaks and drafts.

Interior Amenities

When it comes to the interior of your camper, you can customise it to suit your needs. Consider the layout and include essential features such as cabinets, countertops, a bed, seating area, and a table. You may also want to install electrical components, such as lighting, USB ports, and power outlets. Additionally, think about water systems, such as a sink with a water pump and a small water tank. Solar panels and batteries can provide off-grid electricity for your appliances.

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Building the frame

Materials and Design

Before beginning construction, it's essential to select appropriate materials and design a sturdy frame. While lumber, such as 2x4s or 2x3s, is a common choice, some builders prefer aluminium or steel tubing for their frames due to their lightweight and strong nature. It's important to consider the weight distribution and ensure that the frame can bear its weight and withstand tension and compression forces. Diagonal bracing and triangulating the frame can also add strength and rigidity. Additionally, using plywood for the walls can provide more support to the frame.

Assembly

When assembling the frame, it's crucial to follow the design plans closely. Gluing and screwing the frame together ensures a sturdy structure. For example, one builder used Titebond II glue and 3-inch drywall screws to assemble a 2x2 pine lumber frame. Another builder used a combination of welding and screws to assemble their steel frame.

Exterior and Interior Finish

After assembling the frame, it's time to focus on the exterior and interior finishes. For the exterior, a layer of structural foam insulation is often added to the frame, providing insulation and contributing to the camper's lightweight nature. This is then covered with a layer of plywood, typically 1/4" to 3/4" thick, depending on the surface. The plywood is attached to the frame using glue and staples, although some builders prefer to use adhesive and screws for a stronger bond.

Windows and Doors

When it comes to windows and doors, these can be customised according to your preferences. Some builders opt for a single or multiple side windows, while others include an entry door or a marine hatch for ventilation. It's important to ensure that the frame is sturdy enough to support these features, especially if you plan to include large windows or a front window in the cabover section.

Weight Considerations

Throughout the frame-building process, it's crucial to keep weight in mind. Aiming for lightweight materials and construction techniques will help ensure your cabover camper remains within a manageable weight range for your vehicle.

Final Thoughts

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Insulation and protection

Materials and Techniques for Insulation and Protection:

  • One builder recommends using rigid foam insulation, which is wrapped in canvas and coated with Titebond II (also known as "Poor Man's Fiberglass" or PMF), then painted with rubberized roofing paint. This provides a lightweight, durable, and waterproof layer.
  • Another builder suggests using a combination of plywood and fiberglass. They used 4 and 5.5 mil hardwood ply, sealed with WEST SYSTEM Epoxy, and covered with a layer of 6 oz. fiberglass cloth on the exterior surfaces.
  • For added insulation, consider using structural foam. This will help keep the interior warm and can also reduce windage, improving gas efficiency.
  • To protect the wood from moisture, one builder recommends using fiberglass cloth and epoxy. Another suggests using FRP (fiberglass reinforced plastic) sheets, which can be laminated to the plywood for added strength and weather protection.
  • When it comes to the exterior, some options include canvas, fabric, and paint, or a more traditional fiberglass exterior.
  • For sealing, builders recommend using silicone caulk, Titebond II wood glue, or epoxy.

Design Considerations for Insulation and Protection:

  • When designing the layout, consider the thickness of the insulation and how it will impact interior space. For example, one builder chose to use thinner, 1/4" plywood for the sidewalls to maximize interior space.
  • Think about the climate you'll be camping in and the level of insulation you'll need. For cold weather camping, ensure there is adequate insulation to retain heat.
  • Consider the weight of the insulation and how it will impact the overall weight of the camper. Lighter materials like foam or fiberglass can help reduce weight.
  • If you're using wood, be mindful of the type and quality. Higher-quality, tighter-grain wood may be stronger and more lightweight. Pressure-treated wood may not be ideal as it can take a long time to dry and may not end up straight.
  • For added protection from the elements, consider adding an awning or a roof rack to provide shade and shelter.

Tips and Tricks:

  • One builder recommends using diagonal bracing in the overhead bed area to add strength and rigidity to the structure.
  • When working with wood, consider sandwiching the walls with plywood on both the interior and exterior surfaces, creating a truss structure that is strong and lightweight.
  • If you're looking for lightweight alternatives to wood, consider using aluminium or steel tubing, which can be welded together to create a strong and durable frame.
  • To save weight, focus on insulating the areas where you'll be spending the most time, such as the sleeping area and living space.
  • If you're concerned about condensation, look for materials with good insulation properties, such as the Total Composites camper, which has R-12 insulation and no internal framing to prevent thermal bridging.

Remember, insulation and protection are critical to your comfort and safety while camping. Take the time to choose the right materials, techniques, and design considerations to ensure a successful build.

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Electrical and utilities

The electrical setup of your cabover camper will depend on your power needs and preferences. You can opt for a simple setup with just basic lighting and USB ports, or you can go for a more complex system with appliances such as a refrigerator, microwave, and air conditioner. Here are some detailed instructions and considerations for the electrical and utility systems:

  • Power Source: The first decision to make is the power source for your camper. You can choose between connecting to your truck's battery or installing a dedicated battery system. If you go with the latter, consider using lithium batteries, which are more expensive but offer advantages like safer deep discharging and better cold weather performance.
  • Battery Management: To regulate and protect your electrical system, invest in a quality battery management system. This component will handle charging, discharging, and power distribution. Look for systems that combine multiple functions, like the Redarc Manager30, which includes a converter/charger, solar charge controller, DC-to-DC charger, battery isolator, load disconnect controller, and battery monitor.
  • Solar Power: Consider adding solar panels to your setup. Flexible adhesive solar panels are easy to install and can provide a sustainable power source for your camper. Ensure you have a suitable charge controller to manage the solar input.
  • Lighting: LED lighting is the way to go for your camper. It is energy efficient and can be connected directly to your 12-volt system. LED strip lights are a popular and convenient option.
  • Appliances: If you plan to include appliances like a refrigerator, microwave, or air conditioner, be mindful of their power draw. Calculate the total power requirements and ensure your battery and management system can handle the load.
  • Wiring and Connections: When it comes to wiring, use appropriate gauges for the current you'll be drawing. Consult an electrician or a professional RV installer if you're unsure. Use high-quality connectors, and ensure all connections are secure and well-insulated.
  • Ventilation: Proper ventilation is crucial, especially if you plan to cook inside the camper. Install vents and fans to maintain a comfortable temperature and prevent condensation.
  • Water System: Consider your water needs. You may opt for a simple setup with a manual hand pump and a small water tank or go for a more complex system with an electric pump and larger tank. Ensure you have a plan for greywater disposal.
  • Gas System: If you intend to use propane appliances, such as a stove or heater, consult a professional to ensure safe installation and ventilation.
  • Final Thoughts: Take the time to plan your electrical and utility systems carefully. Consider creating a schematic or using a modelling program like SketchUp to visualise your setup. Always prioritise safety, and don't hesitate to consult professionals if you're unsure about any aspect of the installation.

Remember, the level of complexity you choose for your electrical and utility systems will depend on your specific needs and budget. You can always start with the basics and upgrade or add components later.

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Interior design

Planning and Layout

Before starting the build, it's essential to plan the layout carefully. Consider your specific needs and how you intend to use the camper. Think about the placement of essential components such as the galley, cabinets, seating, and sleeping areas. Utilise tools like SketchUp to create a 3D model and measure the interior space effectively. Decide on the location of appliances, plumbing, electrical systems, and storage solutions. Keep in mind weight distribution and try to maximise floor space.

Materials and Construction

When it comes to materials, opt for lightweight and durable options. Hardwood plywood is a popular choice for framing and interior panelling due to its strength and ability to save weight. Consider using Baltic birch plywood, which is lightweight, strong, and aesthetically pleasing. For insulation, closed-cell foam or rigid foam insulation can be used to fill spaces between framing members. Choose adhesive and screws suitable for the materials you're working with. Corrugated tin or recycled PVC sheathing can be used for roofing, ensuring it's properly sealed to prevent condensation.

Electrical and Plumbing Systems

Electrical and plumbing systems are essential for a functional and comfortable camper. Consider your power sources, such as solar panels, batteries, and power inverters. Install electrical components like lighting, USB ports, and power outlets. For plumbing, decide on a water storage system, such as freshwater tanks or jerrycans. Install a water pump and plan the plumbing lines accordingly. Don't forget to include ventilation to prevent moisture buildup.

Furnishings and Comfort

To make your camper feel like home, add comfortable furnishings. Custom-made cushions, mattresses, and pillows can be added to seating and sleeping areas. Opt for durable and easy-to-clean fabrics, especially if you plan to use the camper in outdoor environments. Consider adding a dining table, which can also double as a cooking or preparation surface. Storage solutions like cabinets, shelves, and nets can help maximise space and keep your camper organised.

Personal Touches and Decor

Add personal touches to make your camper unique and reflective of your style. Choose a colour scheme for the interior panelling or paint designs that appeal to you. Install windows to let in natural light and enhance the sense of space. Consider adding decorations, such as bamboo trim or other accents, to give your camper a cosy and inviting atmosphere.

Frequently asked questions

You can use a variety of materials to build a cab-over camper, including wood, metal, fibreglass, and foam. For example, one builder used 2x2 pine lumber for the frame, 1/8" hardwood plywood for the walls, and fabric and paint (aka "Poor Man's Fiberglass") for the covering. Another builder used 4 and 5.5 mil hardwood ply, sealed with epoxy, with a layer of 6 oz. fiberglass cloth on the exterior surfaces, and 10 oz. fiberglass tape on the corners.

The cost of building a cab-over camper can vary depending on the materials used and the level of customization. Some builders have reported costs ranging from $450 to $1000, while others have spent around $3000 on their projects. It is important to consider the cost of materials, tools, and labour when planning a build.

The tools required will depend on the design and materials used. Basic tools such as a drill, saw, and screwdriver may be needed, as well as more specialized tools like a Dremel tool or a pocket-hole jig for cabinet construction. It is also important to have a workspace where you can safely construct and store your project.

Designing the layout of your cab-over camper involves considering your specific needs and priorities. Some key considerations include maximizing floor space, weight distribution, and the placement of essential components such as the galley, cabinets, and sleeping area. SketchUp is a recommended 3D modeling program that can assist in planning the interior layout.

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