
If you're looking for a truck camper that's easy to store, you may want to consider building your own. While there are commercially available options, building your own truck cap camper can be a great option if you want something that's customised to your needs. In this article, we'll explore the process of making a truck cap camper, including the materials, design, and construction. We'll also look at the benefits of a DIY truck camper and provide some tips and tricks for a successful build. So whether you're an experienced builder or a novice looking for a new project, stay tuned as we dive into the world of truck cap campers!
Characteristics | Values |
---|---|
Materials | Cedar, Liquid Rubber, Baltic Birch Plywood, Fiberglass, Polyurethane Foam, Lithium Batteries, Solar Panels, etc. |
Design Tools | CAD, SketchUp |
Amenities | Bed, Microwave, Refrigerator, Heater, Running Water, Cassette Toilet, Gaming Monitor, etc. |
Safety Features | Clamps, Bolts, Weatherstripping Foam, Seals |
Customization | Modular Design, Removable Camper, Adjustable Systems |
Cost | Varies; approx. $30,000 for the discussed build |
What You'll Learn
Design and planning
The first step in designing a truck cap camper is to consider your specific needs and requirements. For example, if you intend to use it during cold weather, a pop-up camper may not be suitable. Additionally, if you have limited storage space, you may want a camper that can be easily removed and stored when not in use.
Once you have a clear understanding of your needs, you can begin planning the layout and features of your camper. This includes deciding on the placement of essential components such as the galley, batteries, plumbing, stove, and sleeping area. It is crucial to consider weight distribution in this step, aiming to keep the majority of the weight as low and forward as possible to minimise the load between the axles.
Using a 3D modelling program like SketchUp can be incredibly helpful in visualising and planning the interior layout. This software allows you to measure and design the interior space, ensuring that all your desired components will fit and function together seamlessly.
When it comes to materials, there are a few key considerations. For the frame, you may opt for lightweight materials such as cedar instead of plywood to reduce weight. The choice of adhesive is also important—a construction-grade adhesive like Korapop, which is strong and easy to work with, is ideal for gluing surfaces to the walls.
In terms of insulation, R-12 insulation is a significant upgrade over the R-4 insulation found in many competitors. This higher level of insulation prevents "thermal bridging," which occurs when metal components act as a conduit for the cold outside to come inside, leading to condensation issues.
Finally, consider the electrical system and appliances you will need. A 12-volt electrical system is relatively simple to wire, and lithium batteries are a good choice as they are lightweight, long-lasting, and can be discharged fully without risk of damage. Additionally, consider the lighting, water system, heating, and refrigeration you will require, ensuring that you choose high-quality, efficient components that will make your camping experience comfortable and enjoyable.
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Materials and tools
The materials and tools you will need to build a truck cap camper will depend on your specific design and requirements. However, here is a detailed list to get you started:
Frame and Structure:
- Wood: Cedar boards and birch plywood are recommended for the frame and interior structure. Cedar is lightweight and durable, while birch plywood is strong and aesthetically pleasing.
- Insulation: Choose an insulation material with a high R-value to prevent condensation and keep the camper warm in cold weather. Polyurethane foam is a good option.
- Exterior Covering: Consider using a liquid rubber system, including a primer and seam tape, to protect the exterior of the camper from the elements.
- Adhesive: A construction-grade adhesive, such as Korapop, is essential for gluing surfaces and cabinets to the walls of the camper.
- Fasteners: You will need clamps and bolts to secure the camper to your truck bed.
Windows and Doors:
- Windows: Decide on the number and placement of windows. Consider using windows on all four sides for a 360-degree view.
- Sealing: Ensure you have appropriate sealing materials, such as rubber seals and weatherstripping foam, to prevent water ingress.
Electrical and Lighting:
- Batteries: Lithium batteries, such as Battle Born 100 amp-hour batteries, are lightweight, efficient, and can be discharged fully without damage.
- Power Management: A power management system, like the Redarc Manager30, combines multiple functions and simplifies your electrical setup.
- Lighting: LED puck lights and ring lights provide illumination, and you can connect them to a switch and a fuse block.
- Solar Panel: Consider a roof-mounted solar panel, such as the 200-watt Redarc Solar Panel, to charge your batteries and reduce your power consumption.
Plumbing and Water System:
- Water Storage: Use portable water tanks, such as seven-gallon Reliance Jumbotainers, which can be easily removed, filled, and stored when not in use.
- Water Pump: Install a water pump, such as the Shurflo water pump, to facilitate running water in your camper.
- Gray Water Disposal: Decide on a suitable method for gray water disposal, such as draining it through a hole in the camper or storing it in a separate tank.
Heating and Cooking:
- Heater and Stove: Consider a combination unit, like the Wallas Nordic DT, which provides both heating and cooking functions in a compact design.
- Exhaust and Fuel Lines: Ensure you have the necessary components for exhaust and fuel lines, including holes for the exhaust pipe and fuel line.
Interior Furnishings:
- Bed and Mattress: Measure the cabover bed portion of the camper and choose a comfortable mattress, such as the Hest Dually Long, that fits your space.
- Cabinets and Storage: Build or purchase custom cabinets, such as those made from Baltic birch plywood, to store your galley and camping equipment.
- Flooring: A durable outdoor rug from a home improvement store can provide a soft and easy-to-clean surface for your camper floor.
- Seating: Design bench seats that utilize the existing shape of the camper, and add custom pads or cushions for comfort.
- Table: Opt for a swivel table, like the EZ-Reach system, which can be tilted out of the way when not in use and positioned for additional cooking space.
Additional Tools:
- Hole-Saw Bits: Various hole-saw bits will be useful for cutting holes in the camper for exhaust, fuel lines, and other components.
- Pocket-Hole Jig: A pocket-hole jig will assist in joining wood pieces for cabinet construction and other woodworking tasks.
- 3D Modeling Software: Consider using software like SketchUp to plan your layout, measure, and design the interior of your camper.
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Construction
The first step in the construction process is designing the truck cap camper. This involves determining the desired features and amenities, such as windows, insulation, and weight considerations. It is beneficial to use CAD software or a 3D modelling program like SketchUp to create a detailed plan and ensure the camper fits the truck perfectly.
For the frame, consider using lightweight materials such as cedar instead of plywood to reduce weight. The cap can be insulated and covered with a special primer and seam tape, such as Liquid Rubber's full system. Windows can be installed on all four sides for a 360-degree view.
Amenities and features can be customised according to personal preferences and needs. Some options include a bed, microwave oven, portable refrigerator, electric heater, running water with a sink and faucet, a toilet, lighting, and entertainment systems. It is important to consider the weight distribution and ensure that the final product is secure and safe for travel.
The construction of the camper's interior involves building cabinets, installing electrical and plumbing systems, and adding insulation. Baltic birch plywood is a popular choice for building lightweight and sturdy cabinets. Adhesives and screws are used to attach the cabinets to the camper's walls.
Electrical systems typically include batteries, a converter/charger, a solar-charge controller, and lighting. Lithium batteries, such as Battle Born GC2s, are a popular choice due to their lightweight, long lifespan, and ability to function in cold temperatures. For plumbing, a flexible tubing system with removable water tanks can be installed, allowing for easy filling and drainage.
Heating and cooking appliances, such as a diesel stove-and-heater combo, can be installed to suit your needs. Insulation is crucial to ensure the camper stays warm during cold weather camping.
Finally, consider adding storage solutions such as nets, cabinets, and cargo carriers to keep your gear organised and easily accessible.
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Electrical, water, heating and refrigeration systems
Electrical, Water, Heating, and Refrigeration Systems
The electrical, water, heating, and refrigeration systems are crucial components of a truck camper setup, ensuring comfort and convenience during your adventures. Here's a detailed guide on how to approach these systems for your DIY truck cap camper project:
Electrical System:
- Power Source: The electrical system's backbone is a combination of two Battle Born 100 amp-hour, 12-volt lithium batteries. These batteries offer several advantages over traditional lead-acid or AGM batteries, including longer lifespan, higher usable capacity, and lighter weight.
- Battery Management: A Redarc Manager30 system serves as the brain of the electrical setup. It efficiently manages power sources, including solar panels, shore power, and your vehicle's alternator, selecting the most efficient option.
- Lighting: The camper comes prewired with six LED puck lights and a ring light on the ceiling, providing ample illumination.
- Solar Panel: A 200-watt Redarc solar panel mounted on the camper's roof and connected through a standard solar wire port offers a sustainable power source.
Water System:
- Freshwater Tanks: Instead of a built-in tank, opt for two seven-gallon Reliance Jumbotainers as freshwater tanks. They are removable, making refilling and storage convenient.
- Water Pump: Install a Shurflo water pump, which can be retrofitted to the freshwater tanks, to enable running water in your camper.
- Gray Water: Since you'll be boondocking and using biodegradable soap, you can simply let the gray water drain through a hole cut in the front of the camper. Alternatively, you can use one of the water tanks as a gray water tank if needed.
- Hot Water: For hot water and cleaning, install a Geyser system, which efficiently heats water using a built-in 12-volt heater. It provides a sponge bath and saves space and water.
Heating System:
- Wallas Nordic DT: This diesel stove-and-heater combo is a space-saving and functional choice. It serves as both a stove and a heater, and its compact size (approximately 13 x 13 x 7 inches) makes it ideal for your setup.
- Installation: Install the Wallas Nordic DT by cutting a rectangular hole in the countertop for the stove, a small hole for the exhaust pipe, and a tiny hole for the fuel line.
- Functionality: The Wallas Nordic DT has an on/off switch and a temperature dial. When the lid is open, it functions as a cooking surface, and when closed, it becomes a heater with a built-in fan.
Refrigeration System:
- Dometic CRX 80 Electric Fridge: This under-counter refrigerator is highly efficient, pulling around 1.3 amp-hours per hour at 77 degrees Fahrenheit. It offers a spacious 80-liter capacity and can be easily fitted into the cabinets under the stove/heater.
- Flexibility: The Dometic CRX line offers various size options, so you can choose the one that best fits your build.
Remember to refer to local laws, regulations, and safety guidelines when installing and using electrical, water, heating, and refrigeration systems in your truck cap camper.
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Storage and finishing touches
Storage is an important consideration when building a truck cap camper. You'll want to make the most of the limited space and create designated areas for all your camping gear and essentials. Here are some ideas and suggestions for storage solutions and adding the finishing touches to your truck cap camper:
Cabinetry and Shelving
Custom cabinetry and shelving can provide ample storage space and help keep your camper organised. Consider building cabinets with lightweight materials such as Baltic birch plywood, which is strong and aesthetically pleasing. You can use adhesives and screws to secure the cabinets to the walls, ensuring they are sturdy and rattle-free. If carpentry isn't your forte, you may opt to hire a company to build and install custom cabinetry. Don't forget to include a mix of closed cabinets and open shelving to suit your storage needs.
Storage Nets
Storage nets are ideal for bulky yet lightweight items such as blankets, pillows, and clothing. You can install these nets over windows or above the bed, making use of vertical space. They are lightweight, easily accessible, and perfect for items you need to grab quickly.
Exterior Storage
Consider adding exterior storage solutions to your setup, such as a hitch-mounted cargo carrier. This is especially useful if you plan to carry bulky gear like firewood, coolers, or outdoor equipment. Look for welded aluminium options that are strong yet lightweight, ensuring they don't add too much weight to your vehicle.
Custom Pads and Cushions
Custom-made pads and cushions can add both comfort and style to your truck cap camper. Measure your bench seats and sleeping areas, then work with an upholsterer or sewing professional to create custom cushions. Choose durable and thick fabric, such as Sunbrella, to withstand the wear and tear of camping adventures.
Flooring
For a soft and pet-friendly surface, consider a durable outdoor rug that can be easily cleaned. Look for rugs made from materials that are resistant to dirt and moisture. Alternatively, you can opt for rubber flooring or other waterproof options if you prefer a more permanent solution.
Final Touches
Don't forget to add your personal touches and conveniences to make your truck cap camper feel like home. This could include items such as a removable platform for additional sleeping space, fork mounts for secure bike storage, a ski rack for outdoor gear, or an awning for shade and protection from the elements. You may also want to install additional lighting, either inside or outside your camper, to enhance visibility during your camping trips.
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Frequently asked questions
You can use a variety of materials to build a truck cap camper, depending on your preferences and budget. For the frame, you can use plywood or cedar, and for the covering, you can use a liquid rubber system that includes a primer and seam tape. The walls can be made of polyurethane foam sandwiched between two layers of fiberglass, held together with fiberglass extrusions.
You will need various hole-saw bits, adhesive for mounting things to camper walls, and a pocket-hole jig for cabinet construction.
You can use a 3D modeling program such as SketchUp to measure and plan the interior layout of your truck cap camper. Consider factors such as floor space, weight distribution, and the placement of systems and components.
Essential appliances and systems for a truck cap camper include electricity and lighting, running water, a heater, and a refrigerator. You may also want to consider adding a stove, sink, and additional storage cabinets.