Building A Truck Camper: Mimicking The Factory Finish

how to make a truck camper like the factor

Building a truck camper is a rewarding project for those who love to travel and camp. It is a custom, affordable way to have all the comforts of home while on the road. A truck camper is a small camper that slides inside or on top of your truck bed. The advantage of making your own is that you can customize it to meet your individual needs.

There are two main types of truck campers: stationary and removable. Stationary campers are permanently attached to the truck bed, while removable campers use jacks and stabilizers to lift the camper so you can drive your truck under it for installation and removal.

The first step in building a truck camper is to determine the amenities you need, such as a bed, storage, electrical system, plumbing, and insulation. The next step is to build a frame that suits your design, using materials like lumber or aluminium. Once the frame is complete, you side it with plywood to create a rigid structure. Windows, doors, and interior amenities can then be installed. Finally, you finish off the interior with panelling, flooring, and lift jacks if necessary.

Building a truck camper requires careful planning and a range of skills, from carpentry to electrical work. It is important to keep the weight of the camper down while ensuring it is structurally sound.

Characteristics Values
Type Stationary or removable
Materials Plywood, fibreglass, polyurethane foam, aluminium, steel, adhesive, screws, solar panels, electrical wiring, plumbing, insulation, etc.
Tools Hole-saw bits, pocket-hole jig, speed square, T-square, jigsaw, etc.
Design Size, shape, height, weight, windows, doors, etc.
Features Bed, storage, TV, mini-fridge, toilet, sink, electrical system, etc.

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Choosing the right truck cap

One of the most important considerations is the material of the truck cap. The three most common materials are aluminum, fiberglass, and plastic/composite. Aluminum truck caps are usually the most affordable option, often costing less than $1,000. However, they may not be aesthetically pleasing as they are typically white and tend to become dented or dingy over time. Fiberglass truck caps, on the other hand, can be painted to match the colour of your truck, but they are heavier and more expensive, typically costing up to $2,000. Plastic/composite truck caps offer a blend of the pros and cons of aluminum and fiberglass options and are a good middle ground in terms of quality and price.

When choosing a truck cap, it is essential to consider the level of security it provides. Basic truck caps may not offer much security against theft, especially if you plan to store valuable items in the back. If security is a priority, consider a commercial system with a heavier-duty lock made from aluminum or steel. You can also purchase additional locks for toolboxes and drawers inside the bed.

Another factor to keep in mind is the ease of removal. While truck caps are not extremely heavy, their bulkiness can make them difficult to remove without assistance. If you anticipate needing to remove the truck cap frequently, consider choosing a model that can be easily detached and reattached.

Finally, pricing can vary depending on the brand, truck model, bed length, and installation costs. It is worth shopping around and comparing prices from different brands and dealers to find the best option for your budget. Additionally, consider the additional costs of any desired features or customisations, such as windows, shelving, or locking toolboxes.

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Weatherproofing your truck cap

Materials and Preparation:

  • Gather the necessary materials: truck bed insulation tape, aluminium hardware clamps, bolts with threading and washers, a screwdriver, a drill, and a large blanket.
  • Spread out the blanket and place your truck cap upside down on it to protect the cap from scratches.
  • Get a helper to hold the truck cap in place during installation.

Weatherproofing Process:

  • Apply adhesive truck bed insulation tape: Cover the entire bottom of the truck cap with the tape, except for the rear hatch area. This will ensure a tight seal and prevent water or dust from entering. Add extra layers of tape to the bulkhead for added protection.
  • Flip the truck cap right side up: Open the tailgate and, with assistance, carefully place the truck cap onto the pickup truck bed, ensuring it sits evenly on both sides.
  • Secure the truck cap: Apply aluminium hardware clamps against the truck bed rail and cap. If you have a toolbox or other obstructions, you may only be able to clamp down one side.
  • Drill holes: Drill holes on both sides of the truck cap, approximately 24-30 inches apart. The number of holes drilled will depend on the length of your truck bed.
  • Attach bolts and washers: Place a washer on each bolt and insert them into the drilled holes. Screw in the locking nuts to securely fasten the truck cap in place.
  • Check for wiring: Determine if there is a hole near the right rear taillight assembly for the truck cap wiring. If not, drill a small hole to accommodate the wiring.
  • Connect the brake light: Remove the taillight assembly to locate the wiring. Make an incision, strip the casing, and connect the high mount brake light. Connect the brake wire to the truck's brake wire.

Maintenance and Care:

  • Regularly inspect your truck cap for any signs of damage, especially before a trip.
  • Keep the interior clean and free of trash, crumbs, and other debris.
  • Properly manage and store any cables or wires when not in use.
  • Store your truck cap in a safe place when not in use, ensuring it is protected from the elements.

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Installing off-grid electricity

Choose Your Power Source

There are several options for powering your truck camper off-grid. The most common choices are generators, solar panels, wind or water turbines, and fuel from your tow vehicle. Each has its pros and cons, so consider your needs and budget carefully.

Generators are a popular choice as they are relatively inexpensive and easy to use, but they can be noisy and emit harmful fumes. Solar panels are a more eco-friendly option, but they require a significant upfront investment. Wind and water turbines are cheap and clean but may not provide enough power, especially in calm conditions. Using the alternator in your tow vehicle is a good option if you are already using fossil fuels to power your vehicle.

Install Solar Panels

If you choose solar power, you will need to install solar panels on the roof of your truck camper. You will also need to install a charge controller, electrical wiring, and a battery bank to store the solar energy. Ensure you follow the manufacturer's instructions for a safe and effective installation.

Wiring and Batteries

Whether you choose solar or another power source, you will need to wire your system accordingly. For solar, connect the panels to the charge controller and then to the battery bank. Consult a professional or a detailed guide if you are unsure about the wiring process.

It is recommended to use lithium batteries in your setup as they are more efficient, lighter, and longer-lasting than traditional lead-acid batteries. They can also be discharged fully without risking damage, and they work well in cold temperatures. Ensure your batteries are securely installed and well-maintained.

Power Inverter

To use your solar power for devices that require Alternating Current (AC), you will need a power inverter to convert the Direct Current (DC) from the solar panels and batteries. This will allow you to power items such as laptops and other electronics that use AC power.

Test and Maintain Your System

Once your electrical system is installed, test it thoroughly to ensure everything is functioning correctly. Regular maintenance is crucial to keep your off-grid power system in good condition. Check for any signs of damage or wear and tear before and after each trip, and always follow safety guidelines when using your power sources.

Consider Future Upgrades

As you become more experienced with off-grid camping and your power needs evolve, consider upgrading your system. You may want to add more solar panels, invest in a larger battery bank, or explore other power sources. Always ensure your power setup is sufficient for your electrical needs, and don't be afraid to consult experts for advice and guidance.

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Adding a comfortable floor

The floor of your truck camper is a key component that will impact the overall comfort, functionality, and aesthetics of your mobile home. Here are some detailed instructions and considerations to help you install a comfortable floor:

Planning and Preparation:

Before you begin the installation process, it's important to plan and prepare accordingly:

  • Measurements and Layout: Measure the dimensions of your truck bed or the designated floor area accurately. Consider any wheel wells, ridges, or other features that may impact the layout of your floor.
  • Materials and Budget: Decide on the type of flooring material you want to use, keeping in mind your budget and specific needs. Common options include laminate, tile, bamboo, hardwood, foam mats, or modular puzzle mats.
  • Tools and Equipment: Ensure you have all the necessary tools and equipment for the installation. This may include items like a utility knife, straight edge, tape measure, cutting surface, epoxy, paintbrushes/rollers, sandpaper, and safety gear.

Installation Process:

Now, let's go through the step-by-step process of installing a comfortable floor:

  • Surface Preparation: Start by removing any existing flooring or coverings, such as old carpet or linoleum. Clean the subfloor or underlying surface thoroughly by vacuuming and wiping it down with a damp rag to ensure it's free of dust, dirt, or debris.
  • Filling Gaps and Holes: If there are any gaps, cracks, or screw holes in the subfloor, fill them using an appropriate filler or epoxy. This step is crucial for creating a smooth and even surface for your new floor. Allow the filler or epoxy to cure completely according to the manufacturer's instructions.
  • Staining and Sealing (Optional): If you wish to change the colour or tone of your floor, apply a wood stain that complements your interior design. Once the stain is dry, seal the floor with a clear coat of polyurethane to protect the surface and add a shine.
  • Flooring Installation: Begin installing your chosen flooring material, following the manufacturer's instructions. For puzzle mats or modular flooring, lay down the pieces like a puzzle, cutting and trimming as needed to ensure a snug fit. For other flooring types, such as laminate or tile, follow the specific installation guidelines for those materials.
  • Finishing Touches: Once your new floor is installed, take the time to add any finishing touches, such as applying a final coat of polyurethane for added protection and shine, or installing trim or edging to create a seamless transition between the floor and walls.

Maintenance and Care:

To ensure your new floor remains comfortable and durable:

  • Regular Cleaning: Maintain the floor by regularly sweeping, vacuuming, or wiping it down, especially after outdoor adventures to remove dirt, sand, or spills.
  • Repair and Replacement: Should any damage occur, puzzle mats or modular flooring make it easy to replace individual panels. For other flooring types, promptly address any issues, such as scratches or water damage, to prevent further deterioration.

By following these comprehensive steps, you'll be able to install a comfortable and functional floor in your DIY truck camper, enhancing your mobile living experience.

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Building a reclaimed wood wall

Materials:

  • Timberchic (reclaimed wood) in two different sizes: 3” and 5”
  • 1” thick sponge neoprene stripping tape
  • Industrial-strength VELCRO
  • Dremel tool with a saw blade
  • Painter's tape
  • Sheet of printer paper

Process:

  • Install Timberchic on the toolbox: Start by peeling and sticking one plank at a time to cover the flat toolbox surface. Work from one end to the other. Before installing each plank, cover the holes in the wood with the circular black stickers that come with it.
  • Cut the Timberchic to fit the tailgate: Once you reach the bulkhead, you will need to cut the Timberchic to match the tailgate end. Use a Dremel tool for this, as the wood is thin and you want to treat it with care. First, measure where the plank will be cut and use painter's tape to make a straight line. Then, use this cut piece as a template to mark the remaining pieces with tape.
  • Outline the bulkhead with stripping adhesive: Spread the stripping tape on the lower part of the truck cap and the sides, leaving no more than 5” between strips. This will provide a cushioned backing for the thin wood panels.
  • Install Timberchic on the bulkhead: The same measurements and technique used for the toolbox can be applied to the bulkhead installation. The only difference is that the top plank will need to be rounded off. Leave a 1 1/4" gap between the top panel and the roof for the VELCRO strip that will hold the bulkhead curtain.

Now you have a beautiful reclaimed wood wall in your truck camper! This process can easily be adapted and customized to fit the specific dimensions and style of your truck camper. Enjoy your new homey space!

Frequently asked questions

There are two main types of truck campers: stationary and removable. Stationary campers are permanently attached to the truck bed, while removable campers use manual or hydraulic jacks and stabilizers to lift the camper so you can drive your truck underneath for installation and removal. Removable campers offer more flexibility and allow you to use your truck bed for other purposes during camping trips.

Building a DIY truck camper involves several steps, including designing the layout, framing, siding, installing windows and doors, adding amenities, and finishing the interior. It's important to plan the overall design, materials, electrical and plumbing systems, and roofing and siding choices before beginning the build. You can find many online resources and videos that provide step-by-step guidance on building a truck camper.

The materials used for a DIY truck camper build can vary depending on your budget, skills, and preferences. Common materials include plywood, aluminum, fiberglass, and composite panels. For siding, you can choose from options like fiberglass panels, aluminum panels, wood, or even split logs. It's important to ensure that your chosen materials are durable, lightweight, and weatherproof.

The amenities you include in your DIY truck camper depend on your personal needs and preferences. Basic amenities typically include a comfortable bed, storage space, and electrical lighting. You can also add features such as a mini-fridge, toilet, sink, heating or cooling systems, and water tanks. Keep in mind that adding more amenities will increase the weight and complexity of your build.

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