
Campaign signs are a common sight during election season, but what happens to them once the ballots are counted? Instead of tossing them in the trash, why not give them a new lease of life by building your very own campaign sign camper? For around $150, you can create a unique and eco-friendly mobile home. The signs, made from corrugated plastic, are tough, lightweight, and easy to work with, making them an ideal building material. With a little creativity and some basic supplies, you can follow in the footsteps of inventor Paul Elkins and build a bicycle camper that weighs less than 100 pounds. So, if you're looking for a fun and sustainable DIY project, making a camper from campaign signs could be the perfect adventure.
Characteristics | Values |
---|---|
Cost | $150 |
Weight | 45 pounds |
Materials | Corrugated plastic, zip ties, duct tape, pine boards, bicycle wheels |
Features | Sleeping quarters, cooking area, sink, shelves, bins, LED lighting, insulation, skylight, stereo |
Design | Inspired by Airstream trailer, aerodynamic, lightweight, sturdy, waterproof |
What You'll Learn
Using recycled campaign signs
Campaign signs are made from corrugated plastic, which is tough, weather-resistant, and lightweight. Because the signs are layered, you can easily punch holes in them with an awl or ice pick and tie them together with zip ties. They can also be painted. The signs are usually of a uniform size, making construction planning simple.
Inventor and DIY aficionado Paul Elkins has created a design for a bicycle camper made from recycled campaign signs. The design, inspired by the classic Airstream trailer, includes sleeping quarters and a place to cook. Elkins' design uses 1 x 2-inch lumber to build a frame, with salvaged bicycle wheels, and plenty of zip ties and duct tape to hold it together. The total cost of the build is around $150, and the camper weighs about 45 pounds.
Elkins' design plans for the Nomad bicycle trailer are available to purchase on his website for $20. He also offers plans for other projects using recycled campaign signs, such as doghouses, kayaks, and tipis.
To build the frame of the camper, Elkins used six 1"x2" pine boards, which cost under $1 each. He also incorporated cheap electrical plate wheel supports, with a front wheel weighing 3.5 pounds and a rear wheel weighing 4.5 pounds. The total weight of the wheels and frame is 18 pounds, costing under $40.
Elkins cut coroplast panels for the nose of the trailer to create the classic Airstream shape. He joined the panels by punching holes in the coroplast with an awl, using zip ties to connect the panels, and then covered the seams with duct tape. The skylight or upper vent is made from a recycled gallon bucket, with ample caulking added around the edges and a Plexiglas window. A second lid with bug screen instead of Plexiglass can be added for ventilation and to keep the camper cool.
Silver bubble insulation was added to retain heat during the winter, and vents, windows, and the skylight provide air circulation in the summer. The camper includes a sink (made from a bread pan) with a glass water reservoir, food storage shelves (all made from coroplast), a stove (a propane camping stove), and a food preparation area. There are also plastic bins for storing clothing and other items.
Minivans and Popup Campers: A Practical Towing Combination?
You may want to see also
Building a lightweight frame
Choose the Right Materials:
- For a lightweight and sturdy frame, consider using aluminium, fibreglass, or laminated honeycomb foam-filled panels. These materials are strong yet lightweight and can be expensive, so plan your budget accordingly.
- If you prefer to avoid wood due to concerns about rot and deterioration, aluminium and fibreglass are good choices.
- Alternatively, you can use wood strategically. Paul Elkins, a renowned designer, used a very light wooden frame for the bottom of his camper, made from 1x2-inch pine boards. This kept the overall weight low.
Plan for Weight Distribution:
- Before constructing your frame, plan for the weight you expect to carry. Consider the weight of the frame itself, as well as any additional components you plan to add, such as cabinets, dinettes, or sleeping areas.
- If your camper will be towed by a car, ensure you have a steel trailer with sufficient capacity as your base.
Build the Frame:
- When building the frame, consider using lightweight wood such as 2x3s instead of 2x4s to keep the height down.
- Prime and paint the wood to protect it from the elements.
- Use a combination of glue and nails to secure the frame together. For example, use construction adhesive and ring shank nails for added strength.
- Ensure all joints and connections are sturdy and secure.
- If you're building a raised structure, such as a bed platform, consider using lightweight plywood for the flooring.
Consider Additional Components:
- Think about the placement of electrical wiring and lighting fixtures early on, as you'll need to run wires through the frame.
- If you plan to include storage compartments or cabinets, build a base frame for them using lightweight materials.
- For wheel wells, use sturdy materials like plywood and consider coating the inside with a bed liner material to protect against water damage.
Remember, safety should always be a top priority. Consult experts or experienced builders if you're unsure about any aspect of the build. With careful planning and execution, you can create a lightweight and functional frame for your camper.
Truck Camper Compatibility: Longbed Requirements Explained
You may want to see also
Adding wheels and axles
Planning and Materials:
Before you begin, it's essential to plan the placement of your wheels and axles, considering factors such as weight distribution and overall dimensions. Determine whether you'll be using a single-axle or tandem axle setup, depending on the size and weight of your camper. Keep in mind that tandem axles offer better weight distribution and stability, especially for heavier loads.
For materials, you'll need to source wheels, axles, wheel studs, U-bolts, axle pads, and any other relevant hardware. You can often find these at hardware stores, caravan supply shops, or even second-hand from other caravan owners. When purchasing wheels, consider the weight rating of the tyres to ensure they can support your camper's weight.
Assembly:
Start by measuring and marking the placement of your wheels and axles. This includes determining the wheel offset, which is the distance between the wheel's mounting surface and the ground. You can do this by placing the wheel face down and measuring from the ground to the centre of the wheel. This measurement is crucial for ensuring proper wheel alignment.
Next, cut holes in your campaign signs to accommodate the axles. Use an awl or ice pick to make these holes, just like you would when joining the panels of your camper. Secure the axles to the frame using U-bolts, following the manufacturer's instructions. Ensure these are tight and secure to avoid issues with wheel alignment later on.
Now, attach the wheels to the axles. If you're using second-hand tyres, inspect them for any wall damage that could compromise their integrity. Newer tyres may be preferable if you plan on travelling long distances or carrying heavier loads. Ensure the wheels are securely fastened to the axles, following the specific instructions for your chosen wheel type.
Final Adjustments:
Once your wheels and axles are in place, it's time for final adjustments and testing. Measure the distance between your tyres and the caravan chassis rail to ensure adequate clearance. Also, check the wheel alignment by placing a straight edge across both tyres to spot any discrepancies. If you notice any issues, consult a professional or refer to online resources for guidance on correcting wheel alignment.
Finally, consider adding axle pads, especially if your axles are round. These help with axle alignment and can be welded into position. This step can improve the stability of your camper and ensure the axles are centred correctly over the leaf springs.
By following these steps, you'll be well on your way to having a mobile and sturdy campaign-sign camper, ready to hit the open road! Remember to refer to online resources and forums for additional guidance and always practise good craftsmanship for a safe and enjoyable experience.
Camper Shell Tool Box: A Multipurpose Travel Companion
You may want to see also
Sealing gaps with duct tape
When building a camper from campaign signs, sealing gaps with duct tape is an important step to ensure the structure is waterproof and protected from the elements. Here is a detailed guide on how to effectively seal gaps with duct tape:
Prepare the Surface: Before applying duct tape, ensure the surface is clean and dry. Remove any dirt, debris, or residue that may interfere with the adhesion of the tape. It is crucial to work on a smooth and even surface.
Measure the Gaps: Identify the gaps or seams that need to be sealed. Measure the length and width of each gap to ensure you have enough duct tape. It is recommended to have slightly longer strips of tape than needed to ensure complete coverage.
Cut the Duct Tape: Using scissors or a sharp blade, cut the duct tape into strips of appropriate length. Each strip should be long enough to cover the gap with some overlap on both sides. The width of the strips should be slightly wider than the gap to ensure full coverage.
Apply the Duct Tape: Starting at one end of the gap, carefully place the duct tape strip over it, pressing down firmly to ensure good adhesion. Smooth out any air bubbles or creases as you work your way along the gap. Overlap the strips slightly if you need to use multiple pieces of tape to cover the entire length of the gap.
Seal the Corners: Pay special attention to the corners and ensure they are well sealed. Cut the duct tape at a diagonal to create a neat finish when joining two pieces of tape at a corner. Overlap the tape slightly and press down firmly to create a watertight seal.
Check for Airtightness: Once you have applied duct tape to all the gaps, inspect your work and check for any signs of air leakage. Carefully run your hand over the taped areas, feeling for any escaping air. If needed, reinforce any areas that seem to have weak seals.
Maintenance and Repair: Duct tape may need to be replaced over time due to wear and tear or exposure to harsh weather conditions. Regularly inspect your camper for any signs of tape deterioration and replace it as necessary. Keep a roll of duct tape with you during your camping trips for quick repairs.
By following these steps, you can effectively seal gaps in your campaign sign camper, creating a sturdy, waterproof, and weather-resistant shelter. Duct tape is a versatile and inexpensive solution that can ensure your comfort and protection during outdoor adventures.
The Clean Camper Shell: A Tidy Travel Companion
You may want to see also
Adding windows and vents
Now that you've built the frame of your campaign sign camper, it's time to add some windows and vents for light and air circulation. This process can be a bit tricky, but with careful planning and execution, you can successfully install these features. Here are the steps you can follow:
Planning:
Before you begin cutting holes in your camper, it's essential to plan the placement of your windows and vents carefully. Consider the interior layout of your camper and decide on the number and size of windows you want. Remember that windows and vents serve multiple purposes, including bringing in natural light, providing ventilation, and reducing claustrophobia. Additionally, think about the direction of travel and ensure that any drainage holes are at the bottom.
Creating a Template:
Start by creating a template for your window or vent opening. Place the window or vent on a piece of cardboard and trace around it with a marker. Cut out the template and tape it to the inside or outside wall of your camper, depending on its size. Make sure to consider the height of any furniture inside the camper when positioning the template. Once you're happy with the placement, trace around the template to create your cut line.
Drilling and Cutting:
Drill holes along the cut line to connect the dots and create a clear outline. If your cut line is inside the camper, transfer it to the outside by connecting the drilled holes with a marker. Now, it's time to cut out any interior supporting beams using a Dremel or angle grinder. Be very careful during this process, as you don't want to damage the structure of your camper. Finally, use a jigsaw to cut along the marker line, remembering to use the appropriate blades for cutting through sheet metal.
Filing and Treating the Edges:
Once you've cut out the opening, use a metal file to smooth out the edges and remove any sharp burrs. This step is important for safety and to ensure a clean finish. Make sure to vacuum all the metal shavings, both inside and outside the camper, paying extra attention to any double metal skin areas. Treat the bare metal edges with a rust-proof paint to protect them from corrosion.
Installing the Window or Vent:
Follow the manufacturer's instructions for installing the window or vent. Clean the back of the window and the outside of the van with an alcohol wipe. Apply a primer to the edge of the van metal, creating a continuous strip. Then, apply a polyurethane bonding adhesive, warming it in hot water first if it's a cold day. Place the window or vent into the opening, wiggling it slightly to ensure a good seal all around. Use tape to support the installation while the adhesive dries.
Adding Vents for Ventilation:
In addition to windows, consider installing vents to enhance the ventilation in your campaign sign camper. You can choose from various types of vents, including wall vents, floor vents, and roof vents. Wall vents, such as louvred vents or circular vents, provide passive ventilation and are relatively inexpensive. Floor vents are great for constant air circulation and are ideal if you're installing a fridge or gas supply. Roof vents come in many varieties, from simple mushroom vents to fan-assisted vents, offering both passive and active ventilation options.
Remember that proper ventilation is crucial to fight heat, humidity, and pollutants in your small space. It helps regulate airflow, bringing in fresh air while removing stale, damp air. It also reduces stuffiness, combats odours, and prevents the build-up of condensation and mould.
Repairing Water Damage in Your Camper: A Step-by-Step Guide
You may want to see also
Frequently asked questions
The parts cost around $150.
The camper weighs about 45 pounds.
The camper is made from plastic campaign signs, zip ties, duct tape, wood, and bicycle parts.
You can punch holes in the signs using an awl or ice pick and then tie them together with zip ties.