Building A Pop-Top Camper Trailer: A Step-By-Step Guide

Building a pop-top camper trailer is a fun project that can save you thousands of dollars compared to buying a manufactured RV. Constructing your own camper trailer allows you to customize it according to your specific needs, style, and budget. While it requires the right skills, tools, and patience, it can be a rewarding experience that results in a unique and functional camper. In this guide, we will explore the steps to build a pop-top camper trailer, from designing to assembling, and discuss the benefits of choosing the DIY route.

Choosing the right materials

Structural Materials:

The frame of the camper trailer forms its backbone, so choosing a sturdy and durable material is essential. Common options include wood, aluminium, or a combination of both. For example, the Instructables project by Rvanwort used a Universal Roof Rack from Harbor Freight as the base frame, which can support up to 800 lbs. Wood, specifically pressure-treated plywood, is often used for the trailer bed, side walls, and roofing. Spruce is another option for the railing and corners to enhance durability and reduce flex over time.

Fabric and Waterproofing:

The choice of fabric for the pop-top section depends on your preferences and budget. Cotton canvas and vinyl are popular options, with vinyl being more expensive but potentially more durable. Some DIY builders have also used existing waterproof tents for the fabric sections, removing the tent floor and making any necessary modifications. Waterproofing is essential to protect the trailer's interior. One method, called "poor man's fibreglass," involves mixing Titebond II with primer, paint, and bed sheets to create a waterproof coating for the plywood.

Insulation and Interior:

Insulation is crucial for maintaining a comfortable temperature inside the camper trailer. Styrofoam and foam can insulation can be used to fill gaps and provide effective insulation. For the interior walls, stained OSB (oriented strand board) panels can be glued and bolted into place, providing a sturdy and aesthetically pleasing finish.

Braces and Supports:

The choice of braces and supports depends on your design and budget. Simple tent poles can be used, or you could opt for mechanical lifters and braces for more stability. Gas struts are another option, providing a cool deployment mechanism for the pop-up area.

Windows and Ventilation:

Windows play a vital role in natural lighting and ventilation. Consider the number and placement of windows to ensure adequate lighting and airflow throughout the camper trailer. Vinyl windows can be installed in the soft sides of the roof, or you could opt for plexiglass in the hard sides for added durability. Roof ventilation is also essential to prevent heat buildup and maintain a comfortable indoor temperature.

Building the frame

To begin building the frame, you'll need to decide on the materials you'll be using. The frame needs to be sturdy and strong enough to support the weight of the camper and its contents while being towed behind a vehicle. Common materials used for the frame include wood, aluminium, or a combination of both. For instance, you can use a mixture of wood products like plywood and spruce for the trailer bed, side railings, and corners.

When selecting wood, consider using pressure-treated plywood and spruce to enhance the durability and longevity of your frame. The trailer bed can be constructed using a full sheet of 3/4-inch pressure-treated plywood, with the underside painted with a black penetrating paint for added protection. For the side railings, 2x2 spruce provides a sturdy option, while the corners can be reinforced with 2x6 pressure-treated spruce to reduce flex and enhance longevity.

Once you've gathered your materials, follow the instructions provided by the manufacturer of the utility trailer frame. This will serve as the base for your pop-top camper frame. Make sure to carefully measure and cut the wood to the required dimensions. The trailer bed dimensions can be approximately 4 feet by 8 feet, with sidewall heights of 2 feet to match the popup door.

In addition to the trailer bed and side railings, don't forget to include the necessary supports and braces to ensure the structural integrity of the frame. You can also add features like car scissor jacks to the front and rear for enhanced stability.

After completing the basic frame structure, you can move on to adding the necessary openings for lighting, windows, and doors. Cut out the required holes in the frame to accommodate lighting fixtures and wiring. Additionally, consider the placement of windows and doors, ensuring they align with your overall design.

Finally, you can finish the frame by covering it with a suitable material. One option is to use sheet aluminium, which can be purchased from home improvement stores like Home Depot. This adds a sleek and durable finish to your pop-top camper frame.

Remember, building the frame is a critical step, so take your time, measure twice, and ensure a sturdy and safe construction.

Adding walls and a door

Adding walls to your pop-top camper trailer is a crucial step in ensuring its structural integrity, insulation, and overall comfort. Here's a comprehensive guide to help you through the process:

Planning and Materials:

Before you begin construction, it's essential to have a clear plan and gather all the necessary materials. Determine the exact dimensions and layout of your walls, including any windows or access points. Decide on the materials you'll use for the frame, such as wood or aluminum, keeping in mind factors like weight, durability, and ease of construction. For the walls themselves, you can use plywood, with varying thicknesses for the interior and exterior, and don't forget to plan for insulation as well.

Construction Process:

Start by cutting your plywood sheets to size, using the dimensions you determined in the planning phase. Sand the edges to ensure they're smooth. If you're adding windows or doors, cut out the openings accordingly. You can then begin assembling the walls by attaching the plywood sheets to the frame using screws, glue, or other suitable fasteners. Ensure that all joints are securely connected and sealed to prevent leaks.

Insulation and Finishing:

Insulation is key to maintaining a comfortable temperature inside your camper trailer. Cut your chosen insulation material, such as foam board or spray foam, to fit snugly within the wall cavities. You can then cover the insulation by attaching additional plywood sheets or other finishing materials to the interior of the walls.

Adding a Door:

A well-built door enhances the functionality and aesthetics of your camper. Here's a step-by-step guide to installing a door:

Step 1: Measurements and Materials:

Use a tape measure to get the exact dimensions of the door frame. Gather all the necessary materials, including plywood for the door, hinges, screws, a door handle, weather stripping, insulation, and safety gear like goggles and gloves.

Step 2: Cut and Assemble:

Cut the plywood to match the measured dimensions of the door frame. Sand the edges for a smooth finish. Cut and attach additional lumber or framing to the edges of the plywood to create a sturdy door frame. Attach insulation to the inside of the door to help regulate the temperature.

Step 3: Install Hardware:

Screw hinges onto one side of the door, ensuring they are evenly spaced and aligned. Attach the door handle and lock mechanism securely. Apply weather stripping around the edges of the door to prevent drafts and moisture infiltration.

Step 4: Test and Adjust:

Place the door in the frame to check the fit. Make any necessary adjustments to ensure the door opens and closes smoothly. Reinforce the hinges and the area around them with extra wood or metal plates for added support.

Step 5: Finishing Touches:

Apply paint or stain to the door to protect it from the elements and give it a finished look. You can also add decals, stickers, or other decorations to personalize your door.

By following these steps, you'll be well on your way to constructing sturdy walls and installing a functional door for your pop-top camper trailer. Remember to work with precision, ensure all connections are secure, and always put safety first. With careful planning and execution, you'll soon have a reliable and comfortable camper trailer ready for your adventures.

Waterproofing the exterior

Materials:

• Water repellent spray (e.g. Camp Dry Water Repellent Spray)
• Anti-mould and anti-mildew products (e.g. Mold Armor)
• Waterproof cover for the pop-top camper trailer (e.g. PermaPRO Folding Camping Trailer Cover)
• Waterproof spray for the canvas (e.g. 303 High Tech Fabric Guard)
• Seam tape
• Patch kit
• Outdoor caulk (e.g. silicone-based caulk)
• Mild soap
• Soft sponge or scrub brush

Instructions:

• Apply a Waterproof Coating to the Canvas: The canvas surfaces of your pop-top camper trailer should be waterproof, not just water-resistant. Water-resistant coatings can wear off over time, allowing water to soak through. Apply a waterproof spray to both sides of the canvas. This will repel water and keep your trailer dry.
• Use Anti-Mould and Anti-Mildew Products: Mould and mildew can cause health issues and damage your trailer. Use anti-mould and anti-mildew sprays to remove these bacteria and prevent them from growing.
• Keep Your Vents Clean: Regularly clean your vents to remove dust, debris, and dirt. This will help prevent condensation and reduce the risk of mould and mildew formation.
• Use a Waterproof Cover: During the off-season or when your trailer is not in use, cover it with a waterproof cover. This will protect it from rain, snow, and wind damage.
• Clean and Maintain the Canvas: Keep your canvas clean by washing it after each use. This will remove any food residue that might attract animals and prevent acids from bird droppings from damaging the waterproof coating.
• Repair or Cover Any Damage: If your trailer's roof or sides get damaged, repair or cover the affected area as soon as possible. Fibreglass roofs can be repaired with Bondo and resin. For canvas or vinyl siding, use a patch kit for small holes and tears, and replace larger sections if necessary.
• Caulk Vulnerable Areas: The areas around your air conditioner and vent fans are prone to leaking. Remove and replace the caulk in these areas regularly. Use outdoor caulk that can withstand temperature changes, such as silicone-based caulk.
• Be Careful When Opening and Closing: Take care when opening and closing your pop-top camper trailer to avoid tearing the canvas. Ensure that the canvas is not snagged by any opening mechanisms or tree branches.
• Avoid Closing the Camper When the Canvas Is Frozen: Do not close your pop-top camper trailer when the canvas is frozen, as this can lead to tears. Use a heater to thaw the canvas, and open the camper to dry it out before closing and storing it.

Interior design and insulation

Windows

Windows are a critical part of your trailer's insulation. Most campers have single-pane windows, which are not effective at keeping the heat in or the cold out. Consider using clear plastic film to create a faux windowpane. This film sits tight against the window frame and creates a sealed air pocket that resists thermal exchange better than a single pane of glass. You can also upgrade to multi-pane windows, which have two or more panes of glass with a pocket of argon gas in between, providing an even better barrier against thermal exchange.

Doors

Doors are another area of focus when it comes to insulation. You can replace the door with one that has an energy-efficient label or opt for a less expensive option like hanging a thermal curtain in front of the door and using a door snake to block drafts. Don't forget to check the weather stripping and replace it if needed.

Walls, Floor, and Ceiling

When it comes to the walls, floor, and ceiling of your pop-top camper trailer, insulation is key. Fiberglass insulation is a popular choice for trailers as it is relatively inexpensive and effective at insulating against heat and cold. However, it can be a skin irritant, so handle it with care. Spray foam insulation is another option, especially if you have irregular or hard-to-reach spaces. It expands to fill gaps and cracks and provides better insulation than fiberglass.

If you're looking for a lightweight and easy-to-install option, consider foam board insulation. It provides good thermal insulation without adding too much weight. Reflective insulation is also an option, especially if you plan to use your trailer in hot climates. It reflects radiant heat away, keeping the interior cool.

Skirting

Skirting around the bottom of your trailer will help reduce updrafts and keep the heat in. You can buy specialised skirting or make your own by attaching material to the bottom of your trailer. Just make sure to leave enough extra material at the bottom to attach it securely.

Pipes and Compartments

Don't forget to insulate your water and sewer pipes, especially if you plan to camp in cold weather. Wrap your freshwater hose with heat tape and foam insulation to prevent freezing. Also, consider insulating your water heater to reduce heat loss. For the sewer system, use a PVC pipe to reduce the likelihood of freezing.

Other Tips

There are also some other simple tips to help keep your trailer warm. Rugs in uncarpeted areas can retain heat, and slippers or slipper socks will provide an extra layer of warmth. Portable space heaters are another inexpensive way to supplement your heating system, but always make sure to have proper ventilation and a carbon monoxide detector.

Frequently asked questions