Replacing Your Camper Canopy: A Step-By-Step Guide

Changing the canopy on a camper is a complex process that requires careful planning and execution. The canopy, also known as the awning, plays a crucial role in providing shade and protection from the elements. While it may seem like a daunting task, with the right tools, knowledge, and assistance, it can be accomplished successfully. This article will provide a step-by-step guide to replacing the canopy on a camper, covering everything from measuring and choosing the right replacement fabric to releasing the existing awning and installing the new one. By following these instructions, campers can ensure they have reliable shade and protection wherever their adventures take them.

Choosing the right canopy fabric

Fabric Type

The most popular options for canopy fabrics include PVC-coated polyester, vinyl laminated polyester, and traditional canvas. PVC-coated polyester is the standard choice for many tents and marquees due to its low maintenance, lightweight, and economical characteristics. It is also waterproof and resilient to harsh weather conditions. Vinyl laminated polyester, on the other hand, offers improved weather resistance and UV stability while maintaining portability. Traditional canvas canopies, made from 100% cotton, are less common nowadays but provide a classic and natural look.

Durability

When choosing a canopy fabric, consider the durability of the material. Look for fabrics that are resistant to wear and tear, sun exposure, and harsh weather conditions. Check manufacturer ratings and material specifications to gauge the expected lifespan of the fabric. Some fabrics, like polycarbonate, can maintain their integrity for over a decade, while others, like uncoated polyester, may degrade in just a few years.

Weather Resistance

Ideal canopy fabrics should be able to withstand outdoor conditions such as moisture, heat, wind, and UV rays. Compare weather resistance between fabrics by checking features such as waterproof and UV protection ratings, colourfastness properties, and heat reflection capabilities. For example, vinyl-coated polyester typically has a higher waterproof rating than uncoated polyester, while polycarbonate blocks almost 100% of harmful UV rays.

Weight and Portability

The weight of the fabric will impact the ease of transport and setup. Lighter materials like polyester are more portable and easier to set up, while heavier options like polycarbonate may require multiple people to move and erect the canopy. Consider your priorities when choosing the weight of the fabric, as the lightest fabrics may sacrifice some durability or weather resistance.

Aesthetics

Canopy fabrics come in a variety of colours and styles. Consider the aesthetic you want to achieve, whether it's a vibrant and colourful canopy or a more translucent or clear option that maintains surrounding views. You can also add side walls and accessories to complement the chosen fabric's appearance.

Budget

Lastly, consider your budget when choosing a canopy fabric. PVC-coated polyester and traditional canvas options are typically more affordable, while fabrics with advanced features and longer lifespans, like vinyl laminated polyester and polycarbonate, may come at a higher cost.

Installing the canopy

Step 1: Measure and Plan

Before starting the installation, it is crucial to take accurate measurements of your truck bed and supplies. Determine the size of the equipment you plan to store underneath the sleeping platform to ensure it fits comfortably. Consider the height and length of the compartments you will need. It is recommended to design the platform in three sections: two outer boxes that go over the wheel wells and a centre section that ties the outer edges together. Don't forget to allow for a support board in the middle to prevent sagging. Using software like Google SketchUp or good old-fashioned pencil and paper, create a layout that suits your needs.

Step 2: Gather Materials and Tools

For the installation process, you will need plywood (2-3 sheets depending on the size of your truck bed), fastening supplies like angle brackets, bolts, T-nuts, and screws, hinges, carpet, duct tape, a saw (preferably a circular saw with a guide), an electric drill, a ratchet and sockets for bolts, and a staple gun.

Step 3: Cut the Boards

Carefully plan how you will cut the boards to minimise waste and reduce costs. Leave a 1/8" gap around cut edges to account for the saw blade width. Cut the boards lengthwise first, then cut them to length using a radial arm saw for square cuts. Ensure the boards fit around any tie-down hooks and other obstructions in the truck bed.

Step 4: Fasten the Boards

To make installation, removal, and storage easier, fasten all boards to brackets with bolts and T-nuts. It is recommended to assemble the entire platform outside the truck bed for more space to work. If necessary, add supports to the top centre boards to ensure they rest securely on the support boards. You can use 1 1/2" angle iron for added stiffness and to save space.

Step 5: Add Finishing Touches

Cover the top boards with carpet for a finished look and to protect your mattress. Cut the carpet to fit each piece, secure it with staples, and finish the edges with duct tape. Sand all visible edges to prevent tearing. You may also want to finish the boards to extend their lifetime.

Step 6: Install the Platform

After you are satisfied with the assembled platform, dismantle it and reassemble it inside the truck bed. By fastening the sections with bolts, you can easily install it in the confined space. Add your mattress, and your camping setup is ready! If you use a foam mattress, consider cutting it into several cushions for easier access to the under-bed storage.

Fixing a sagging canopy

Once the cause of the sagging has been identified, you can begin the process of fixing it. Here is a step-by-step guide:

Step 1: Gather the Materials

You will need the following items:

• 4 pool noodles or cylindrical insulation tubes (you may need more or less depending on the affected area)
• A sharp knife or similar cutting tool
• A ladder, if the sagging is high up
• An extra pair of hands to help lift the fabric

Step 2: Cut Notches

Use the knife to cut some notches where the pool noodle will meet the support beams of the canopy. This step is optional but helps to keep the noodles in place. Be careful not to cut too deeply, as you don't want to cut the noodle in half.

Step 3: Lift the Fabric

Have your assistant lift the fabric while you insert the pool noodle between the canopy and the support beams. This step ensures easy access to insert the foam tubes.

Step 4: Fix the Noodle in Place

Check that the ends of the pool noodle are securely wedged between the fabric and the lateral support beams. The notch should be aligned with the support beam. Repeat this process for the other three corners of the canopy, or more if your canopy has an irregular shape.

And that's it! Your sagging canopy should now be fixed, and you can enjoy your camping trip under a tight and taut tent. Remember to inspect your canopy regularly to avoid having to deal with sagging in the future.

Replacing the canopy arms

Step 1: Loosen the Awning Bolts

First, roll out the awning from the camper. You only need to extend it by about a foot. Loosen the four bolts (two on each side) holding the arms to the sides of the camper. Also, remove the screws in the fabric channel at the top of the awning, so that the fabric can slide back and forth easily.

Step 2: Remove the Awning

Lift the awning slightly and walk it down the channel, away from the camper. Be careful not to scratch the sides of the camper. Lay the awning on the ground, preferably on blocks to make it easier to work with.

Step 3: Remove the Arm

Go to the left or back side of the awning (the side without the extend/retract lever). There should be a small hole on the end cap, sometimes concealed by a plug. Insert a small pick or screwdriver into this hole to lock the spring tension on this side. Then, move to the front side of the awning. Remove the bolt holding the arm to the bracket, and then remove the arm from the roller. Keep a tight hold on the bracket while doing this, as the spring is still under tension.

Step 4: Release the Tension

You will need a bracket on the roller to release the tension. If the bracket remains in place when you remove the arm, you don't need to do anything. If the bracket comes off, temporarily replace it on the roller and insert a bolt to secure it. Take hold of the bracket and rotate it slightly forward so you can return the selector lever to the retract position. Rotate the bracket slowly until the spring unrolls all the way. Keep count of how many rotations this takes, as this will be important later when securing the right amount of tension with the new fabric.

Step 5: Remove the Cap/Spring Assembly

If you are working on the front side of the awning (with the extend/retract lever), mark the lever position on the cap and roller tube with a marker. This will be important when reassembling these parts. Remove the bolts, screws, or rivets holding the end cap in place, and set it aside.

Step 6: Prepare the New Fabric

Unroll the new fabric and mark each of the two channels with a distinct letter or symbol. The main section is attached to the camper, and the smaller decorative valance section hangs down.

Step 7: Install the New Fabric

Slide the end of the valance section's cord into the channel marked "V", and the end of the main section's cord into the channel marked "M". Work the fabric into the channels and slide it into place, with a helper holding the other end of the fabric taut. Center the fabric as closely as possible using a tape measure. Pull the fabric to one side and measure the distance between where the end cap will end and where the fabric begins. Divide this number in half and move the fabric to that point.

Step 8: Put the Awning Back Together

With your helpers, roll the fabric up in the opposite direction you took it off. Reinstall the spring assembly, ensuring that any marks you made line up. Hold the bracket in position and reinstall the arm, replacing the screw that holds it in place.

Step 9: Replace the Awning on the Camper

With your helpers, lift the arms of the awning against the camper and walk the awning in slowly as someone feeds the fabric back into the channel. Make sure the lower section of the legs are locked in.

Step 10: Double-Check the Awning

Find the pull rope and hook it with your awning rod, or have a helper grab one arm while you grab the other. Slowly pull the awning out and make sure it rolls out evenly, with the fabric not bunched to one side. If the awning seems crooked or bunched, slide the fabric left or right along the track to even it out.

Maintaining the canopy

Inspect your canopy regularly: Check for damage, holes, or mould on the canopy fabric, especially before and after the camping season. Look for wear and tear on the bungee fasteners and structural components like poles. Aim to inspect your canopy twice a year, once in spring and once in fall.

Clean your canopy regularly: Use mild soap and water to clean the canopy fabric. Avoid harsh chemicals and abrasive cleaning tools, as they can damage the material. Rinse with a garden hose and let it dry naturally.

Prevent mould and mildew: Avoid rolling up a wet awning. If you must, make sure to reopen and dry it as soon as possible. Clear leaves and debris before rolling up the canopy to prevent moisture buildup.

Secure your awning: Use awning clamps to prevent the awning from opening while driving and to reduce flapping in the wind.

Adjust the pitch: Angle one corner of the awning downward to allow for water runoff. Avoid steering too close to the dumping location to prevent an unexpected shower.

Be cautious when opening: Ensure the awning clears the top of your door, and alert your travel companions before opening to avoid accidental tears from a swiftly opened door.

Retract in high winds: Most awnings can handle moderate winds, but it's better to be safe than sorry. Retract the awning if you're unsure about wind speed or if you're leaving the campsite.

Frequently asked questions