Creating A Camper Rockguard: A Diy Frontal Protection Guide

Rock guards are a common feature on campers and RVs, protecting the front window from rocks and other debris while on the road. They are also known as stone guards or window rock guards. While some campers come with factory-installed rock guards, others may require a custom-made solution. In this guide, we will explore the different options for creating a rock guard for your camper, including buying a new or used one, repairing an existing one, or making one from scratch. We will also discuss the benefits of rock guards, such as added protection and shade, as well as considerations for removing them when not in use. Whether you're an experienced camper or just starting out, this guide will help you make an informed decision about rock guards for your RV.

Measure and cut the material for the frame

To measure and cut the material for the frame of your camper's rock guard, follow these steps:

First, you'll need to measure the dimensions of your camper's front window, as the rock guard will need to be larger than the window to provide adequate protection. Allow for at least 1" to 2" of extra material around the window, depending on whether you plan to use prop rods or rock guard support arms to hold the guard in place.

For the frame, you can use 3/4" Aluminium U Channel, which you can find at most hardware stores. Measure and cut the U Channel to size, adding a few extra inches to each side to account for mitred corners. You will also need angled mending plates (with 2 screw holes in each leg) to reinforce the corners of the frame. Cut and mitre the U Channel material to form a rectangle that is slightly larger than your window, and join the corners with the mending plates, ensuring they are positioned at the bottom edge of the channel.

At this stage, you can also add hinges to the top of the frame so that you can attach it to the camper later. You will also need to attach hasps to the bottom of the rock guard, so you can lock it into place for travel.

Once you have the basic frame constructed, you can lay a bead of LEXEL Sealant along the inside edge and set a piece of plexiglass into the frame. This will provide a clear view through the window while also protecting it from rocks and debris. Cut the plexiglass to size, allowing for a slight overlap with the frame (around 1/4" should be sufficient).

Finally, measure and cut a second piece of U Channel to fit along the bottom edge of the plexiglass, creating a channel to hold it in place. Secure this piece with pop rivets, and your rock guard frame is complete!

Assemble the frame

To assemble the frame for your camper's rock guard, you will need to determine the size of the frame. The rock guard should be larger than the front window by at least 1"-2" all the way around.

Once you have determined the size, you can begin constructing the frame. You will need to purchase or cut aluminium U-Channel to the appropriate size. Miter the corners of the U-Channel and connect them using angled mending plates and pop rivets. Ensure that the mending plates are attached to the inside corners of the frame and are kept towards the bottom edge of the channel. Only attach the mending plates to two corners at this stage.

Next, you will need to create a seal for the frame. Apply a bead of LEXEL Sealant to the inside of the frame and place a piece of plexiglass into it. The plexiglass should be approximately 1/4" thick. Once the plexiglass is in place, attach the remaining mending plates to the corners and rivet them into place. Set the frame aside, face down, and allow the sealant to dry. You may need to add an additional bead of sealant to the inside edge of the plexiglass and U-Channel for a secure seal.

At this stage, you should have a basic frame for your rock guard. The next steps will involve adding hinges and latches to attach the rock guard to your camper and ensure it stays in place during travel.

Attach the frame to the camper

Now that you have your frame ready, it's time to attach it to your camper. Here are the steps you can follow:

• Measure and mark the spots on your camper where you want to attach the hinges for the rock guard frame. Typically, you'll want to attach the hinges above the window of your camper, but you can adjust the placement based on your preferences and the design of your camper.
• Drill holes at the marked spots. Make sure the holes are large enough for your screws to fit through.
• Attach the hinges to the camper using screws and a screwdriver. You may also need to use a drill for this step, depending on the type of screws you're using.
• Now, attach the rock guard frame to the hinges. You may need an assistant to help hold the frame in place while you attach it. Make sure the frame is securely attached to the hinges and can move freely.
• To keep your rock guard in place during travel, attach latches or locks at the bottom of the frame. You can use hasps and small padlocks, as mentioned in one of the forum posts.
• If you want to be able to prop your rock guard open, you can add support arms or prop rods. These can be attached to the bottom of the frame and then to the camper body when you want to keep the rock guard open.
• Test the movement of your rock guard to ensure it opens and closes smoothly and securely. Make any necessary adjustments to the hinges or latches.

By following these steps, you should now have a securely attached rock guard frame on your camper! You can now enjoy added protection for your camper window and a stylish new accessory for your travels.

Cut and fit the window material

When cutting and fitting the window material for your camper's rock guard, you have a few options to consider. The material you choose will depend on your specific needs and preferences, as well as the design of your camper. Here are some options to consider:

Option 1: Polyester Resin and Boat Cloth

If you have a smooth surface rock guard, you can repair holes using polyester resin and boat cloth. First, ensure that the polyester resin will adhere well to the existing material. Then, apply at least three layers of boat cloth and resin to the back of the cover, making each layer bigger than the previous one. This will provide strength and holding power to the repair.

Option 2: Tiger Hair and Body Filler

After applying the boat cloth and resin, use Tiger Hair (a thickened version of resin with coarse chopped fiberglass strands) to fill in the hole. Be careful not to overfill, as it will get rock hard, and grinding down the excess can be challenging. Once the Tiger Hair is flush with the surface, use body filler to fill in any remaining coarse holes. Sand down the filler until it is smooth and flush with the surface.

Option 3: Fiberglass Reinforced Panel (FRP)

Another option is to use Fiberglass Reinforced Panel (FRP), which can be purchased at hardware stores like Home Depot or Lowes. Place your old rock guard on the FRP and trace around it to create a template. Cut out the FRP using a jigsaw with a fine blade or a thin cutoff wheel on a grinder. Remember to use a good-quality dust mask to protect yourself from fiberglass particles during the cutting process. Fit the cut FRP into the frame to ensure it is the correct size, and make any necessary adjustments.

Option 4: Vinyl-Coated Aluminum Panel

If you prefer a more durable option, you can use a vinyl-coated aluminum panel for your rock guard. Cut the pieces to size and form bends using a siding brake. This option may require the assistance of a professional siding specialist to ensure a proper fit.

Option 5: Clear Vinyl or Padded Vinyl

If you're looking for a temporary solution, you can create a clear or padded vinyl cover for your windows. Attach the cover with Velcro or snaps, allowing you to remove it when not in use. This option is ideal if you want to maintain visibility through the windows while towing and can be a cost-effective solution.

Remember to take precise measurements and plan your cuts carefully to ensure a proper fit for your window material. Always wear the appropriate safety gear, including eye protection and dust masks, when cutting and fitting the material.

Paint or decorate the rockguard

Once you've built your rock guard, you might want to paint or decorate it to match your camper's colour scheme or to add a personal touch. Here are some ideas for how to do this:

Painting Your Rock Guard

If you want to paint your rock guard, you'll need to choose the right type of paint. Exterior paint designed for use on aluminium, metal, or vinyl surfaces would be a good option. You can find these types of paint at most hardware stores. Before you start painting, be sure to clean the surface of the rock guard to remove any dirt or debris. Once the surface is clean, you can apply a primer designed for use with the type of paint you've chosen. After the primer has dried, you can start painting. Use a brush or roller to apply the paint evenly, and be sure to follow the instructions on the paint can for the best results.

Decorating Your Rock Guard

In addition to painting, you can also decorate your rock guard with vinyl stickers or decals. You can find a variety of stickers and decals online or at craft stores. If you're feeling creative, you can even design and cut your own vinyl decals using a cutting machine. Another option for decorating your rock guard is to add some lighting. You can find adhesive LED lights that can be attached to the rock guard, or you can install lights along the edge of the guard. These lights can add a unique touch to your camper and improve visibility at night.

Maintenance and Care

To keep your painted or decorated rock guard looking its best, be sure to clean it regularly. Use a mild soap and water solution to remove any dirt or debris, and be sure to rinse and dry the surface thoroughly. If the paint starts to chip or peel, you may need to sand and repaint the affected areas. With proper care and maintenance, your painted or decorated rock guard will look great for years to come.

Frequently asked questions