Building An Aluminum Camper: A Comprehensive Guide

how to make aluminm camper

Building an aluminium camper is no small feat, but with the right tools and know-how, it can be done. One way to go about it is to use a combination of aluminium and very high bond (VHB) tape, which can cost upwards of $4000 in parts and take around 250 hours of labour. Alternatively, you can use laser-cut aluminium parts and a welder to fabricate the shell, but this method is tricky and time-consuming. If you're looking for a simpler approach, consider using a pre-fabricated frame and aluminium siding, or even building a wooden frame and skinning it with aluminium. Whichever route you choose, be prepared for a challenging but rewarding project that will require careful planning and execution.

shunauto

Welding vs. riveting

When it comes to building an aluminum camper, there are two main methods for joining metal components: welding and riveting. Both have their advantages and limitations, so it's important to understand the differences to make an informed decision.

Welding is a process that uses heat to fuse two or more pieces of metal together, creating a permanent bond. It offers high structural integrity and can be used to create aesthetically appealing, continuous seams. Different types of welding include spot welding, tack welding, fuse welding, stitch welding, seam/fillet welding, Metal Inert Gas (MIG) welding, and Tungsten Inert Gas (TIG) welding. Welding is ideal for creating strong, waterproof seams, making it suitable for parts that require high structural integrity, such as frames. However, welding can be time-consuming, requiring a high level of skill and potentially increasing labor costs and lead times. The heat involved in welding can also cause distortion and discoloration, especially in thin metals like aluminum.

On the other hand, riveting is a mechanical fastening method that uses rivets to join two pieces of metal together. Riveting is typically faster and more cost-effective than welding, making it suitable for simple structures and prototyping. It also doesn't require any post-installation cleanup and can join different types of metals, such as aluminum and steel, or stainless and galvanized. However, rivets are visible and may not meet aesthetic requirements. Additionally, riveting may not be as strong as welding, especially for parts that need to withstand heavy loads or forces that draw the pieces apart.

When deciding between welding and riveting for your aluminum camper, consider your needs. If aesthetics and consistency are critical, welding might be the better choice. If you're working with a tight budget or timeline, riveting could be a more suitable option. Additionally, combining both methods can offer the best of both worlds, such as using welding for visible areas and riveting for concealed sections to reduce costs.

shunauto

Insulation

When it comes to choosing insulation materials, there are a few options. Foam board insulation is a popular choice due to its efficacy, high R-ratings, good resistance to mould, and ability to prevent air leaks. Polyiso board (PIR) is one of the best foam board insulations and is also more environmentally friendly than other types of foam board. It is recommended to use this type of insulation on the floor, roof, and walls of the camper.

Another option is van insulation roll, also known as blanket or batt insulation, which is woolly in texture and comes in rolls. 3M Thinsulate insulation rolls and Hempitecture HempWool are recommended options for filling awkward spaces in the camper.

For tight gaps where batt insulation won't fit, spray foam insulation can be used. However, it is important to note that spray foam can be a health hazard during installation and can cause 'super-heating' which could lead to warping of the metal.

To insulate the floor of the camper, it is recommended to first lay strips of Reflectix to lower the e-value and trap air between the floor and the foam. Then, lay down wooden furring beams and install the foam board insulation. Install a plywood subfloor and you're ready to put down your floorboards.

For the walls, build a wooden support frame and then install polyiso foam board panels. Fill any gaps with batt insulation or spray foam.

For the roof, install wooden support beams and stick strips of Reflectix to the troughs to lower the e-value and create an air insulator. Then, stick polyiso foam board to the roof.

It is important to consider the health and safety risks when installing insulation, such as ensuring proper ventilation and wearing appropriate protective gear.

shunauto

Framing

First, you need to decide on the type of framing material. Aluminum is a popular choice due to its lightweight and durable nature. You can weld aluminum frames or build a wooden frame and skin the outside with aluminum. If you choose to weld, it is essential to have the proper equipment and experience. Another option is to use standard off-the-shelf steel studs, which can provide a sturdy frame for your camper.

When designing the frame, consider the overall size and shape of your camper. Determine the length, width, and height that best suit your needs and vehicle. Consider the angle of the walls and roof, ensuring they align with the vehicle's factory exit angles. Think about the placement of doors, windows, and other openings. Additionally, plan for any interior features, such as storage compartments or cabinets, and ensure the frame accommodates them.

The next step is to cut and assemble the frame. If you're using aluminum or steel, you may need to weld the pieces together. Alternatively, you can use rivets or high-bond tape to join the frame components. Ensure all connections are secure and aligned correctly. Consider reinforcing the frame with additional support, such as box tubes or angle iron, for added strength and stability.

Before moving on to the next stage, carefully inspect the frame for any imperfections or weak spots. Ensure that all measurements are accurate and that the frame is sturdy enough to support the weight of the completed camper. Make any necessary adjustments or reinforcements to ensure a solid foundation for the rest of the build.

Finally, consider the insulation and thermal break for your aluminum camper. Metal conducts heat and cold efficiently, so it is essential to prevent temperature transfer and condensation. You can use spray foam, sheet foam, or fiberglass insulation between the framing. Spray foam is effective in sealing air leaks but can be expensive and challenging to work with if repairs are needed. Sheet foam, on the other hand, provides a reliable R-value and can be cut to fit the spaces in the framing.

shunauto

Windows and access doors

When it comes to windows and access doors for your aluminium camper, there are several options and steps to consider.

Firstly, decide on the type of windows you want. Radius side sliding, radius front sliding, radius 90-side sliding, and radius side bay windows are all options offered by camper shell manufacturers. You can also opt for acrylic dual-pane windows, which offer better insulation and noise reduction. These windows often come with built-in blackout blinds and bug screens, providing both privacy and ventilation.

Next, determine the location of your windows and doors. Consider the amount of space available and any potential factors that might prevent you from installing them in specific locations. It is essential to plan this carefully to ensure functionality and ease of use.

Now, let's move on to the installation process. You will need to create a template for each window and door. Start by tracing the desired size onto a piece of cardboard or OSB plywood, using the centre flange on the door frame as a guide. Cut out the template and test its fit. Repeat this process until you are satisfied with the size and placement.

Once you have the perfect template, tape it to your vehicle and trace the outline with a sharpie. Use a drill bit to start a point for your jigsaw and carefully cut along the traced lines. File down any rough edges and ensure you spray any exposed steel with Rust-Oleum to prevent rusting.

Test fit your windows and doors to ensure they sit properly in the openings. You may need to make adjustments to the openings or the frames for a perfect fit.

For the window and door frames, you can use Baltic Birch plywood or another type of wood of your choice. Cut the frames to size, ensuring they fit snugly around the openings. Glue, clamp, and screw the frame pieces together, allowing them to cure overnight.

To install the windows and doors, follow the manufacturer's instructions. You will typically need to attach washers or screws to the frame and corresponding holes in the vehicle. Ensure you use the appropriate drill bit size for your screws. Test the fit of your windows and doors, making any necessary adjustments.

Finally, seal the windows and doors with caulk or another suitable sealant to prevent leaks and ensure a snug fit. Allow the sealant to cure according to the manufacturer's instructions before using your new windows and doors.

Remember to take precise measurements, plan your locations carefully, and always test fit before final installation. With careful planning and execution, you can successfully install functional and aesthetically pleasing windows and access doors in your aluminium camper.

shunauto

Interior design

When it comes to the interior design of your aluminium camper, there are several factors to consider. Firstly, you'll want to decide on the layout and functionality of the space. Consider what features and amenities are most important to you. Some common elements in camper interiors include a bed, storage compartments, a kitchenette, and seating. Think about how you plan to use the space and what furnishings and fixtures will be necessary to support your activities.

Once you've determined the layout and functionality, you can start thinking about the specific materials and design elements. For the walls and ceiling, you might opt for lightweight materials such as plywood or panelling. This will help keep the overall weight of the camper down, improving fuel efficiency and handling. Consider using extruded aluminium for the framing, as it is strong, lightweight, and resistant to expansion and contraction. This can be sourced from suppliers like 8020.net or Grainger, or for faster shipping, Amazon.

For insulation, spray foam is a popular choice, as it seals air leaks and provides good thermal protection. However, it can be expensive and difficult to repair. An alternative is sheet foam, which offers a similar R-value (a measure of thermal resistance) without the hassle of spraying. When it comes to fastening panels to the aluminium frame, consider using slide-in economy T-nuts with flanged button head socket cap screws. These are easy to use and provide a strong connection.

Finally, think about the overall aesthetic you want to achieve. Do you prefer a modern, minimalist look, or a cozier, more rustic style? Choose colours, fabrics, and finishes that reflect your taste and personality. Remember to consider the weight and durability of the materials you select, as every addition will impact the overall driveability of your camper.

Frequently asked questions

There are a few ways to build an aluminum camper. You can weld a frame or build a wooden one and use aluminum to cover the outside. You can also use standard off-the-shelf steel studs.

Aluminum is a lightweight material, making it a good choice for a camper frame. It is also durable and can be welded, riveted, or taped together.

It is important to consider the design and engineering of the camper, not just the custom fabrication. You will also need to plan out access for systems such as water and heating, and include a thermal break to prevent heat and cold conduction.

Written by
Reviewed by
Share this post
Print
Did this article help you?

Leave a comment