Transforming Pop-Up Campers: Hard-Sided Makeover

Converting a pop-up camper to a hardside camper is a complex and costly process that requires significant modifications to the original structure. The project involves removing the soft canvas or vinyl sides and replacing them with rigid materials such as wood, metal, or fibreglass. While it is possible to fabricate foldable hard sides, the majority of the discussion revolves around permanently raised hard sides. This type of conversion is uncommon, and there are few examples of successful implementations. The cost, time, and effort required for such a project are considerable, and it may be more practical to purchase a new camper or explore alternative solutions, such as repairing or replacing the canvas.

The cost of converting a pop-up camper to hardside may be three times the cost of a new camper

Converting a pop-up camper to a hardside model is an exhilarating and fulfilling endeavour that can enhance your camping adventures. However, it is important to note that the cost of such a conversion may be three times the cost of a new camper. This is because the process involves significant modifications and the use of specialised materials.

Firstly, the existing canvas walls need to be replaced with sturdy solid panels, such as plywood or fiberglass. Plywood is more affordable and easier to install, but fiberglass provides superior insulation and moisture resistance. The choice of materials depends on the budget and preferences of the camper owner.

Secondly, reinforcing the camper's frame and roof is crucial to support the weight of the hard walls and prevent leaks or damage. This may involve adding support beams or braces, as well as reinforcing the corners with metal brackets or angle supports.

Thirdly, insulation is essential for maintaining comfortable temperatures. Different types of insulation, such as reflective bubble wrap or fibreglass, can be used depending on the specific needs and constraints of the project.

Additionally, installing electrical and plumbing systems is a crucial aspect of the conversion process. This includes setting up a deep-cycle battery, converter, AC breaker panel, and freshwater and greywater tanks. These systems provide power, lighting, and water supply, making the camper functional and convenient.

Finally, the interior finishes, such as flooring, paint, and furniture, contribute to the overall comfort and aesthetic appeal of the converted camper. Upgrading these elements can greatly enhance the appearance and functionality of the space.

While converting a pop-up camper to a hardside can be a rewarding project, it is important to carefully consider the costs involved. The materials, labour, and specialised equipment required for the conversion can quickly add up, potentially exceeding the cost of purchasing a new camper. Therefore, it is essential to weigh the benefits of the conversion against the financial investment required.

The axle and frame of a pop-up camper are designed to support the weight of canvas, not wood

When considering converting a pop-up camper to hardside, it is important to remember that the axle and frame of a pop-up camper are designed to support the weight of canvas, not wood. This means that if you plan to use wood for your hardside conversion, you will need to address the added weight. One way to do this could be to use a lighter-weight material for the sides, such as sheet metal, fiber-reinforced paneling, or sheet fiberglass. While it is possible to use wood, keep in mind that the cost and weight of the material will need to be factored into your plans.

Another option to consider is to make the sides foldable, which can help distribute the weight more evenly. This can be done by using hinged panels that allow the top to still be cranked up and down, or with solid panels that can be manually put in place. If you choose to go with solid panels, you will need to plan for how they will be stored when not in use, as they will take up additional space.

Additionally, when converting to hardside, you will need to consider the wind load that the new structure will create. Pop-up campers are designed to collapse, and the added weight of hardside walls can put extra strain on the frame and axle. To address this, you may need to reinforce the frame and axle to ensure they can handle the additional weight and wind load. This could involve adding gussets, cutting, and welding to strengthen the structure.

It is also important to keep in mind that a hardside conversion will likely be a time-consuming and expensive project. The cost of materials, especially wood, can be high, and the labour involved in the conversion can be intensive. There may also be additional costs for specialty tools and hardware. As such, it is important to carefully plan and budget for your conversion project.

Overall, while it is possible to convert a pop-up camper to hardside, it is important to carefully consider the added weight, wind load, cost, and labour that will be involved.

The pros and cons of converting to hardside include weight, cost, and the time it takes to complete the project

Pros and Cons of Converting to Hardside

Converting a pop-up camper to hardside has its advantages and disadvantages. The pros and cons of such a conversion include weight, cost, and the time it takes to complete the project.

Weight

One of the main drawbacks of converting to hardside is the added weight. Hardside campers are heavier than soft-side campers, and this extra weight can put a strain on your vehicle. It's important to check the weight towing capacity of your car before making any modifications. Smaller cars may struggle to pull the added weight of a hardside camper.

On the other hand, some hardside campers, particularly A-frame campers, are designed to be lightweight and easy to tow. These campers typically weigh around 2000 lbs or less, making them a more manageable option.

Cost

Converting to hardside can be an expensive undertaking. The materials alone can be costly, and if you're not handy, you may need to hire someone to do the work for you. In some cases, the cost of converting to hardside can be three times the price of buying a new trailer. It's important to consider the financial investment required before starting such a project.

Time

Converting a pop-up camper to hardside is not a quick process. It requires a significant amount of time and effort, especially if you're doing it yourself. There will be a lot of planning, trial and error, and potential setbacks along the way. Additionally, if you're planning to tow your camper on roads, you'll need to ensure that your conversion is road-safe, which can add to the time and complexity of the project.

While the conversion process may be time-consuming, one advantage of hardside campers is that they are typically quicker to set up and take down at the campsite. This can be a benefit if you're looking to save time and get camping faster.

One way to convert a pop-up camper to hardside is to use foamie walls to replace the canvas

To start the conversion, you'll need to source foam wall panels that are lightweight and easy to install. You can find these panels at home improvement stores like Home Depot or online retailers like wallsupply. The panels come in a variety of styles, including brick, stone, wood, and concrete textures, so you can choose the look that best suits your taste.

When selecting your foam wall panels, pay attention to the coverage area and thickness of the panels to ensure you purchase enough for your camper. You'll also need to consider how the panels will fold or collapse when the camper is in transit. One suggestion is to use foam core board to create panels that can be fitted into place once the top of the camper is raised. These panels can be made lightweight and durable, but you'll need to consider how to seal them against the weather and attach them to the base.

Another option is to create foldable walls, similar to those found in fold-a-wall campers or Apache Ramada campers. These walls are made of a sandwich of aluminum, styrofoam insulation, and plywood or wood veneer, and they fold inward when the camper is collapsed. You can also find windows for your new hard sides from travel trailers or other camper styles.

Keep in mind that converting a pop-up camper to hardside is a significant project that may cost more and take longer than expected. You'll need to address weight distribution, axle and frame support, and wind load concerns to ensure your camper is safe for travel.

Another way to convert a pop-up camper to hardside is to use sheet metal, fiber-reinforced paneling, or sheet fibreglass

To start, you'll need to remove the soft sides of the pop-up camper. This typically involves taking out the interior, except for any fittings you plan to reuse, and retaining only the shell. It's important to note that reinforcing the camper's frame and roof is crucial before installing the new panels. This will ensure the structure can withstand the weight of the hard sides and provide stability.

When choosing the type of paneling, consider the purpose of your camper. If you plan to use it for camping, hunting, or fishing trips, sheet metal or fiberglass may be ideal as they are lightweight yet sturdy. On the other hand, if theft deterrence or maintaining a constant temperature is a priority, fiber-reinforced paneling or heavier materials like plywood could be a better option.

Once you've selected the appropriate material, cut the panels to size, allowing for flat storage inside the converted camper when it's collapsed. This way, you can still tow the camper conveniently and benefit from reduced wind resistance. Remember to number the panels and their respective locations if you wish to disassemble and reassemble the structure easily.

Finally, use spray glue or contact adhesive to hold the panels in place. For added protection, insulate the corners with external ribs and use canisters of expanding foam inside. This will help prevent drafts and maintain the desired temperature inside your newly converted hardside camper.

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