Transforming A Pop-Up Into A Cozy Camper

how to make a camper from a pop up

Building a pop-up camper is a fun project that can save you thousands of dollars. Constructing your own pop-up camper allows you to customise it according to your needs and ensures that you are confident in the quality of your build. It is important to note that some campgrounds restrict the types of campers they allow, so it is a good idea to check this before you begin.

The first step in building a pop-up camper is deciding whether to build it on a trailer or in the back of a truck. If you choose to build on a trailer, it is recommended to start with an existing trailer as it may be difficult to register, license, or insure a homemade one.

The next step is to decide between a hard-sided or soft-sided camper. Hard-sided campers require more engineering to deal with the weight of the materials, while soft-sided campers typically use canvas walls for flexibility.

Once you have made these initial decisions, you can start gathering the materials and creating a design plan. This step is crucial as it will determine the cost and complexity of your build. After finalising your design, you can start ordering parts and building your camper.

Building a pop-up camper can be a challenging but rewarding project that will elevate your camping experiences.

Characteristics Values
Cost of parts $4,000+
Labour time 250 hours
Build time 4 months of weekends
Weight 400 lbs
Materials Aluminium, wood, canvas, vinyl, waterproof tents, glue, screws, struts, braces, tent poles

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Choosing a base for your camper

If you choose to build your pop-up camper on a trailer, you'll have more space to work with and potentially more flexibility in your design. However, it's important to consider the added cost and complexity of registering, licensing, and insuring a homemade trailer, which may vary depending on your location. It's recommended to start with an existing trailer to make this process easier.

On the other hand, if you opt for building in the bed of a truck, you'll need to carefully consider the weight and size restrictions of your vehicle. This option may be more feasible if you already own a suitable truck and are comfortable with the space constraints. Keep in mind that you'll likely need a lift or extra sets of hands to move and place the pop-up camper onto your truck.

Another aspect to consider is whether you want a hard-sided or soft-sided camper. Hard-sided campers offer more protection and may be preferable for extreme weather conditions, but they also add weight and complexity to the lifting mechanism. Soft-sided campers, on the other hand, typically use canvas or vinyl walls, making them more lightweight and compact.

When choosing a base for your camper, it's crucial to take into account the overall weight of your vehicle, its tow ratings, and the comfort and functionality you desire. Additionally, think about the materials you'll be using for the frame, fabric, braces, and supports, as these will impact the weight and durability of your pop-up camper.

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Designing the structure

Next, you'll need to decide between a hard-sided or soft-sided pop-up camper. Hard-sided campers offer more protection but require careful consideration of weight and the mechanism for lifting the pop-up. Soft-sided campers typically use canvas or vinyl walls, providing flexibility and compactness.

The frame of the camper is a crucial component. It needs to be sturdy enough to support the structure during transport and when set up. Common materials for the frame include wood and aluminum, or a combination of both. The choice of material will impact weight, cost, and durability.

For the fabric section of the camper, you can use cotton canvas, vinyl, or even existing waterproof tents. If you're handy with a sewing machine, you can sew the fabric together. Alternatively, vinyl glues can be used to avoid sewing altogether.

When it comes to braces and supports, you have options like simple tent poles, mechanical lifters, or gas struts to help deploy the pop-up area. The choice depends on your budget and desired level of complexity.

Before starting construction, it is essential to draw up a detailed design plan. Consider the exact dimensions, materials required, and any unique features you want to include. Creating a digital model using CAD software can be immensely helpful. Unfortunately, there are limited blueprints or kits available online for pop-up campers, so you may need to get creative and innovative with your design.

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Selecting materials

Weight and Durability:

  • Choose lightweight materials to ensure your camper is easy to tow and pop up.
  • Opt for durable and weather-resistant materials to withstand various conditions. Waterproof materials will keep your camper in good condition.
  • Consider using a combination of wood and aluminum for the frame to achieve both sturdiness and lightness.

Exterior and Interior:

  • For the exterior, aluminum siding is a popular choice due to its lightweight and durable nature. It is readily available and gives a modern look to your camper.
  • Prioritize lightweight and sturdy materials for the interior. Plywood or similar materials are good options to maintain a low overall weight.
  • Ensure proper insulation to maintain a comfortable temperature. Foam insulation between wall layers is effective for regulating temperature.

Hardware and Assembly:

  • Select high-quality hardware, such as screws, nails, hinges, and struts, for a secure and stable structure.
  • Consider using gas struts to help with the deployment of the pop-up area.
  • Keep weight in mind when choosing hardware to avoid adding strain to your vehicle.

Customization and Cost:

  • Building a pop-up camper allows you to customize it according to your needs and preferences. You can choose materials that fit your budget and specific requirements.
  • Sourcing recycled or second-hand materials can help reduce costs.
  • Take advantage of deals at local hardware stores or online marketplaces to find budget-friendly options.

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Building the frame

Planning and Materials

First, you need to decide on the materials for your frame. The most common options are wood and aluminium, and you can also combine both. Aluminium is lightweight and strong, but it can be more expensive. Wood is a more affordable option and is easier to work with for beginners.

Construction

When constructing the frame, ensure it is sturdy enough to support the camper while being towed and during setup and use. Here are the key steps:

  • Base Frame: Start by building the base frame, which will be attached to your trailer or truck bed. Ensure it is securely fastened to the foundation, following the guidelines mentioned earlier.
  • Wall Frames: Build the wall frames, which will provide the structure for your canvas or vinyl walls. These should be attached to the base frame with hinges, allowing for the folding or collapsing mechanism.
  • Roof Frame: Construct the roof frame, which will also be attached with hinges to allow for the pop-up function. Ensure the hinges are sturdy and of high quality to withstand repeated use.
  • Bracing and Supports: Add bracing and supports to the frame to enhance its stability. You can use simple tent poles, mechanical lifters, or gas struts, depending on your design and budget.
  • Test and Reinforce: Once the basic frame is constructed, test its stability and reinforce any areas that seem weak. The frame should be able to withstand some flex while being towed and during setup, so ensure it has some give but is not too rigid.

Final Steps

After constructing the frame, you can move on to the next steps of your DIY pop-up camper build, including:

  • Fabrication: Choose your fabric, which is typically cotton canvas or vinyl. You can also use a waterproof tent as a cost-effective option.
  • Attachments: Decide on the method for attaching the fabric to the frame, such as sewing, gluing, or using J-channels and Velcro.
  • Accessories: Plan for any additional features you want to include, such as windows, insulation, or plumbing.
  • Testing: Finally, test your pop-up camper frame by setting it up and ensuring all the mechanisms work smoothly and securely.
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Adding plumbing and wiring

Plumbing and wiring are two of the most complicated aspects of converting a pop-up into a camper. The first step is to decide on the placement of your plumbing and wiring. It is important to keep in mind that the weight of the water will affect the balance of your camper. Therefore, it is recommended to place your water tanks over the wheel axle.

Next, you will need to decide on the size of your water tanks. This will depend on how much water you will need and how much space you have. To calculate the size of your fresh water tank, you should first estimate your daily water usage by breaking down how much water you will need for cooking, drinking, washing dishes, and showering. Then, multiply this number by the number of days you want to go between refills.

For example, if you estimate that you will need 15-20 litres of water per day, and you want to be able to go 5-7 days between refills, you would need a 100-litre fresh water tank.

Once you have determined the size of your water tanks, you will need to choose the type of water tank. There are two main types of water tanks: standard shape and over-the-wheel-well. Standard shape water tanks are box-shaped and tend to be the most cost-effective option. Over-the-wheel-well water tanks are placed over the wheel axle, making them more space-efficient.

After you have chosen and installed your water tanks, you will need to install a water pump. The water pump pressurises your water system and should be placed on a 12V switch so that you can turn it off when it is not in use. It is also recommended to install an accumulator after the water pump to smooth out the pressure changes.

Now, you will need to decide on your points of use, which are the fixtures where you will be using water. These can include a shower, sink, or UV purifying faucet. It is recommended to have all of your points of use on one side of the camper to simplify the plumbing installation.

Next, you will need to install your grey water tank, which collects the used water from your points of use. The size of your grey water tank will depend on the size of your fresh water tank and how often you want to empty it. As a general rule, grey water tanks are typically half the size of the fresh water tank.

Finally, you will need to connect all of the components of your plumbing system using tubing and connectors. It is important to use flexible tubing, such as braided vinyl or PEX, to navigate the tight spaces in your camper.

When it comes to wiring your camper, the first step is to determine the size of your electrical system. This will depend on the number and type of appliances you plan to use. To calculate the size of your electrical system, you will need to estimate your daily power usage by calculating the amp-hours for each appliance.

To do this, divide the wattage of each appliance by the voltage (typically 12V for a camper). Then, multiply this number by the number of hours the appliance will be used per day to get the total amp-hours used per day. Add up the amp-hours for all of your appliances to get your total daily power usage.

Once you have determined your daily power usage, you can choose the size of your battery bank. It is recommended to have enough battery capacity to last at least 3-4 full days without charging. To calculate the size of your battery bank, multiply your total daily power usage by the number of days you want to go without charging.

For example, if your total daily power usage is 94 amp-hours, and you want to be able to go 4 days without charging, you would need a battery bank with a capacity of at least 376 amp-hours.

After you have determined the size of your electrical system, you will need to choose the type of batteries you will use. The two most common types of leisure batteries for campers are AGM (Absorbent Glass Mat) and lithium. AGM batteries are more affordable, while lithium batteries are smaller, lighter, and have a longer lifespan.

Once you have chosen your batteries, you will need to decide on a charging method. There are several options for charging your batteries, including solar panels, a battery-to-battery charger, or a shore power hookup. If you plan to use solar panels, you will also need to install a solar charge controller.

Next, you will need to choose an inverter, which converts the 12V power from your batteries to 230V so that you can power standard appliances. There are two types of inverters: quasi (modified) sine wave and pure sine wave. Quasi sine wave inverters are cheaper but may not be compatible with all appliances, while pure sine wave inverters are more expensive but can power a wider range of appliances.

After you have chosen your inverter, you will need to install a fuse box to protect your electrical system in case of a power surge. The size of your fuse box will depend on the number of appliances you have. Finally, you will need to connect all of the components of your electrical system using wires, connectors, and a busbar.

It is important to note that plumbing and wiring a camper can be complex and may require specialised knowledge and tools. If you are unsure or uncomfortable with any part of the process, it is recommended to consult a professional or seek advice from experienced individuals.

Frequently asked questions

Building your own pop-up camper can save you thousands of dollars. You can also customise it to your needs, choosing the materials you want to use, and ensuring the craftsmanship is solid.

You will need wood, aluminium, canvas or vinyl for the walls and roof, and simple tent poles, mechanical lifters or gas struts to help deploy the pop-up area. You will also need a plan, design and bill of materials before you start.

The cost of parts for a DIY pop-up camper can be upwards of $4000, with some people spending $6000 on materials. The cost will depend on the complexity of your design, the materials you use, and the features you want to include.

Building a DIY pop-up camper can take anywhere from 100 to 250 hours of labour, depending on your skills and experience. It is important to plan and prepare before you start building, to ensure the process goes smoothly.

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