Transforming Your Pickup Box Into A Cozy Camper

how to make a camper out of a pickup box

How to Make a Camper Out of a Pickup Box

Turning a pickup truck into a camper is a great way to create a mobile living space for adventures on the road. It requires a fair bit of work and a range of tools and materials, but the end result is a custom-built camper tailored to your needs. Whether you're an experienced builder or a novice, with enough time and patience, it's possible to design and construct a unique camper setup. This article will introduce the topic and provide an overview of the process, with links to more detailed guides for specific steps in the build.

Characteristics Values
Purpose To build a camper that can be easily loaded and unloaded from a pickup truck
Target Audience People who want to bring out the wild in themselves; aspiring full-time RVers or weekend adventurers
Cost $1,500
Tools Hammer drill, wrench set, Dremel tool, heavy-duty fabric scissors, non-fabric cutting scissors
Materials Camper mounting tape, bolts, washers, nuts, timber, glue, VELCRO, screws, staples, fabric, paint, glass, silicone caulk, square trim, electrical boxes, LED strips, etc.
Time A few weeks to a few months
Difficulty Moderate to difficult
Benefits More space and comfort than a tent; weatherproof and off-grid electricity; customisable

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Choosing the right materials

The materials you choose for your pickup truck-to-camper conversion will depend on your budget, the level of comfort you want, and how much customisation you plan to do.

If you're on a tight budget, consider using second-hand or recycled materials where possible. For example, you could use an old mattress and cut it to size, or repurpose an old table to create a kitchen counter.

For the exterior, you'll need materials that are durable, lightweight, and waterproof. Plywood is a good option for the frame, as it's sturdy and relatively inexpensive. You can cover the plywood with a fabric and paint mixture, also known as "Poor Man's Fiberglass", which is lightweight, durable, and waterproof. Alternatively, you could use aluminium or fiberglass sheets, although these may be more expensive and require specialised tools to work with.

When it comes to insulation, closed-cell foam is a popular choice as it's lightweight and effective at keeping the heat in. For the electrical system, you'll need batteries, a power inverter, solar panels, and various cables and connectors. Lithium batteries are a good option as they're lightweight, long-lasting, and can be discharged without risking damage.

For the interior, consider using lightweight materials like Baltic birch plywood for cabinets and benches. This type of plywood is strong, lightweight, and aesthetically pleasing. For the flooring, you could use a durable outdoor rug, which can be easily removed for cleaning. Finally, don't forget to include storage solutions like nets, shelves, and cargo carriers to maximise the space in your new camper.

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Building the frame

Planning and Materials

Before you begin construction, it is important to have a clear plan and gather the necessary materials. Determine the desired dimensions and layout of your camper, taking into account factors such as available space, intended use, and personal preferences. For the frame itself, consider using 2 x 2 pine lumber, which can be more cost-effective than purchasing 2 x 4s and ripping them with a table saw. You will also need an appropriate adhesive, such as Titebond II, and screws (3-inch drywall screws are a good option). Additionally, you may want to use a table saw to rip some of the lumber into thinner pieces for certain parts of the frame.

Assembly

When assembling the frame, start by cutting the lumber to the required lengths based on your plan. Join the pieces together using both the adhesive and screws for a strong bond. Be generous with the adhesive, as you want to ensure a solid connection between the pieces. Use clamps to hold the pieces in place while the adhesive dries.

Covering the Frame

Once the frame is assembled and the adhesive is dry, it's time to cover it. One option is to use 1/8" hardwood plywood, which can be glued and stapled to the frame. Make sure to apply the adhesive evenly and smoothly to the plywood before attaching it to the frame. After the glue dries, you can remove the staples as they are no longer needed and can show through the covering.

Finalizing the Frame

Before moving on to the next steps of your camper build, inspect the frame to ensure it is sturdy and secure. Make any necessary adjustments and double-check that all connections are tight and stable. Remember, this frame will serve as the foundation for your camper, so it needs to be robust and capable of withstanding the weight and stresses of your camper setup.

Additional Tips

  • Consider using a combination of adhesives and screws for a stronger hold.
  • Take precise measurements and cut your lumber accordingly to ensure a snug fit.
  • Allow adequate time for the adhesive to dry completely before moving on to the next steps.
  • If you plan to paint or treat the frame, do so after assembly and covering, following the manufacturer's instructions for the best results.
  • Always prioritize safety when working with power tools and follow proper procedures.
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Installing windows and doors

Planning and Preparation:

First, decide on the number, type, and location of the windows. Consider factors such as cost, security, ventilation, and natural light when making your decision. The most popular types of windows for camper vans are bonded windows and framed acrylic windows. The location of the windows will depend on the interior layout of your van.

Next, source the windows and the necessary tools and materials. You can purchase windows from suppliers like Van Pimps, Van Windows Direct, Leisure Vehicle Windows, and Jacksons Leisure. You will also need a jigsaw, a hammer, a metal file, a drill, rust-proof paint, primer, sealant or adhesive, and window trim (optional).

Drilling and Cutting:

Create a guide for the jigsaw by drilling holes from the inside of the van, using the seam as a guide. Tape the area around the cut to protect the paint. Place a cardboard box below the cutting area to catch sparks and prevent them from marking the paintwork. Start cutting the hole for the window, using goggles and gloves for protection. Once a large section has been cut, use padding between the van and the cut part of the metal for support.

Filing and Painting:

After cutting the hole, use a metal file to smoothen the edges and remove any sharp burrs. Vacuum all the metal shavings and apply rust-proof paint to the bare metal edges.

Applying Primer and Adhesive:

Apply primer to the window edges and the van, ensuring it dries completely before proceeding. Warm the adhesive or sealant, if necessary, and apply it in a continuous bead around the edge of the window or the van, ensuring there are no gaps.

Installing the Window:

Lift the window and press it firmly onto the adhesive. Make any necessary adjustments to ensure even gaps. Secure the window with tape to prevent slipping while the adhesive dries. Leave it for several hours or overnight for the adhesive to fully set.

Attaching Window Trim:

If desired, attach window trim along the inside of the window to cover the sharp edge. Ensure any glue or sealant is dug out before attaching the trim.

Additional Considerations:

  • Always wear protective gear, including goggles and gloves, when cutting and drilling.
  • Work in a well-ventilated area and allow ample drying time for primers and adhesives.
  • Consult professionals or seek advice from online resources and communities if you are unsure about any part of the process.

By following these steps, you can successfully install windows in your camper van, creating a comfortable and functional space for your adventures.

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Electrical systems

Planning the Electrical System:

  • Determine Power Needs: Before designing the electrical system, it is essential to assess your power requirements. Identify the electrical appliances and devices you plan to use and calculate their power consumption. Consider factors such as lighting, refrigeration, fans, electronic charging, and entertainment systems.
  • Select Battery Type and Size: Choose between 12V or 24V systems, depending on your needs. Calculate the total amp-hours (Ah) required for your daily use and select a battery with sufficient capacity. Consider deep cycle batteries designed for frequent discharging and recharging.
  • Choose a Solar Setup: Solar panels are a great way to generate electricity for your camper van. Determine the amount of solar power needed based on your power requirements and available roof space. Decide on the number and wattage of solar panels, keeping in mind that they can be connected in parallel to increase output.
  • Consider Other Charging Methods: In addition to solar, you may want to include other charging methods such as charging from the vehicle's alternator while driving or connecting to shore power at campsites.

Installing the Electrical System:

  • Battery Installation: Install the batteries in a secure and well-ventilated location. Ensure they are properly secured to prevent shifting during travel. Connect the batteries in parallel or series, depending on your voltage requirements.
  • Wiring Basics: Use appropriate gauge wires for your system, ensuring they can handle the current drawn by your appliances. Always disconnect the power source before working on the electrical system. Use proper tools for stripping and crimping wires.
  • Fuse and Breaker Protection: Install fuses and breakers to protect your electrical system from overcurrent and short circuits. Fuses are typically used for DC circuits, while breakers are used for AC circuits. Place them as close to the battery as possible.
  • Distribution Panels: Utilize a distribution panel or fuse block to manage and organize your electrical connections. This will allow you to connect multiple devices and provide a central location for troubleshooting.
  • Inverter Installation: If you need to power AC devices, install an inverter to convert DC battery power to AC power. Ensure the inverter is properly sized for your power requirements and connected to the distribution panel.
  • Solar Panel Installation: Mount the solar panels on the roof of your camper van, ensuring they are securely attached and angled to maximize sun exposure. Connect the solar panels to a charge controller, which regulates the charging process and protects your batteries from overcharging.
  • Shore Power Connection: If desired, install a shore power inlet to connect to external power sources at campsites. This will typically involve installing a power inlet, a transfer switch, and proper wiring to your electrical system.
  • Lighting and Appliance Installation: Install lighting fixtures, fans, and other appliances, ensuring they are properly wired and connected to the appropriate fuses or breakers. Test each component to ensure proper functioning.
  • Grounding and Bonding: Ensure that your electrical system is properly grounded and bonded to the vehicle's chassis. This is crucial for safety and will vary depending on your specific setup.

Remember to consult with a professional electrician if you are unsure about any aspect of the electrical system installation, especially if you have limited experience with electrical work.

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Interior design

The interior design of your pickup truck camper is a very personal choice and will depend on your needs, budget, and level of DIY expertise. Here are some ideas and considerations to help you get started:

Layout and Space

Decide on the layout and functionality of your space. Consider how you will use the camper—will you need a dedicated sleeping area, a kitchen, a dining area, or a combination of these? Think about how much space you will need for each function and how you can maximize the limited space. For example, you could have a dining table that folds down into a bed, or a couch that converts into a sleeping area.

Materials

When choosing materials for your interior, consider factors such as weight, durability, insulation, and aesthetics. Plywood is a common choice for building cabinets, shelves, and sleeping platforms due to its lightweight and strength. For flooring, consider using a durable outdoor rug that can be easily cleaned and rolled up when not in use. If you want a more permanent flooring solution, you can use tongue-and-groove panels or stick-on tiles for a more finished look.

Windows and Ventilation

Windows not only provide natural light and ventilation but can also make your space feel larger and more open. Consider adding windows or skylights if your camper does not have them already. You can also install privacy screens or curtains for added privacy and to block out light when needed.

Electrical System

If you plan to have electrical power in your camper, you will need to decide on a power source. Options include connecting to your truck's battery, installing solar panels, or using a portable power station. Consider your power needs and budget when choosing a system. You can also install LED strip lights or puck lights to brighten up your space.

Storage

Storage is crucial in a small space. Utilize vertical space by building cabinets, shelves, or bins. You can also install hooks or hanging storage for items such as pots, pans, or towels. Consider adding storage bins or compartments under benches or the sleeping area to maximize space.

Comfort and Decor

To make your camper feel like home, add comfortable cushions, pillows, and blankets. You can also bring in decor items such as rugs, curtains, or wall hangings to add colour and personality to your space.

Plumbing and Appliances

If you plan to include plumbing and appliances, such as a sink, shower, or stove, carefully plan their placement and ensure you have the necessary connections and power sources. Consider space-saving options such as a sink cover that increases counter space or a combination stove and heater.

Frequently asked questions

The tools you will need include a hammer drill, a set of wrenches, a Dremel tool with saw blades, heavy-duty fabric scissors, and non-fabric cutting scissors.

Materials include camper mounting tape, bolts, washers, nuts, timber, glue, VELCRO strips, and fabric for curtains and a ceiling cover.

You will need an inverter, lithium batteries, solar panels, and a DC-DC charging system.

Consider the weight distribution and try to keep the weight as low and as far forward as possible. Also, think about how you will use the space and what features are most important to you, such as a full-size door or a removable panel for loading kayaks.

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