Creating A Custom Awning For Your 66 Frolic Camper

how to make an awning for 66 frolic camper

If you're looking to make an awning for your 66 Frolic camper, there are a few options to consider. You could opt for a fixed or van-mounted awning, with the latter offering the convenience of being permanently mounted. Alternatively, a portable or removable awning might better suit your needs, as they can be set up and taken down with ease. When it comes to materials, you could go for a simple tarp or upgrade to a more durable fabric like canvas or ripstop nylon. Whatever your choice, a bit of creativity and ingenuity will go a long way in crafting the perfect awning for your camper.

Characteristics Values
Awning type Fixed, rolling out from a rack mounted to your van, or removable
Removable awning type Simple canopy that mounts to the side of your RV, or standalone tent
Roll-out awning type Simple, frameless; crank-operated; motorized
Materials Polyester; polyethylene; canvas; vinyl; ripstop nylon
Awning maintenance Clean regularly; ensure awning dries out before storing
Awning repair Tape repair kits; patching

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Choosing the right materials

Fabric Type

The fabric you choose will significantly impact your awning's performance and longevity. Some common options include:

  • Polyester is a popular choice for modern awning tents due to its lightweight, mildew-resistant, and UV-resistant properties. It is also generally cheaper to produce and easier to maintain. However, it is less durable than other options and challenging to repair if torn.
  • Polyethylene is even lighter than polyester but falls short in terms of durability and UV resistance.
  • Canvas is a traditional, natural fabric known for its durability and breathability. It creates a comfortable environment by regulating temperature and reducing condensation. However, it is heavier and more expensive than polyester. Canvas also requires more care, as it needs to be completely dry before storage to prevent mildew.
  • Vinyl is highly waterproof and UV-resistant, making it ideal for protecting against the elements. It is also easy to clean. However, vinyl is not breathable, making it susceptible to mould and mildew growth if not properly ventilated.
  • Ripstop nylon is considered one of the best fabrics for awnings due to its durability, lightweight, waterproofing, and UV resistance. However, it is also the most expensive option.

Fabric Weight and Thickness

The weight and thickness of the fabric are important considerations, as they impact the awning's overall durability and resistance to tears. Thicker fabrics, measured in mils, provide more resistance to tears, while heavier fabrics, measured in ounces per square yard, can indicate higher quality. However, weight alone does not determine quality, and other factors like weave count and denier should also be considered.

Water Resistance and Breathability

Water resistance is crucial for an awning to provide effective shelter from rain. While some fabrics like polyester and vinyl offer excellent water resistance, they may lack breathability, leading to condensation buildup. On the other hand, natural fabrics like canvas are highly breathable, ensuring a comfortable environment but requiring more careful maintenance to prevent mildew.

Durability and Maintenance

The durability of the fabric will determine how long your awning lasts and how much care it needs. More durable fabrics like canvas and ripstop nylon can withstand rugged environments and frequent use, but they may require more maintenance to prevent mildew or discolouration. Weaker fabrics like polyester are more prone to tearing and may only offer short-term repairs.

Ease of Cleaning

Consider the ease of cleaning and maintenance when choosing your awning fabric. Fabrics that are easier to clean, such as vinyl, may require less frequent maintenance, while fabrics like canvas may need regular treatments to prevent staining and discolouration.

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Making the awning frame

Planning and Materials

Before you begin, it is important to plan the dimensions of your awning frame. Measure the width of the area you want to cover, taking into account the size of your camper and the desired amount of shade. Determine the length of the ledger board by measuring from stud to stud, adding 3 inches to account for the end rafters.

For the materials, you will need:

  • Exterior-grade 2x4 lumber (cedar, pine, or redwood)
  • 3-inch exterior-grade structural screws
  • 2 1/2-inch exterior-grade structural screws
  • Exterior-grade wood filler (optional)
  • Paint and primer or wood stain (optional)
  • Covering material of your choice (awning fabric, corrugated plastic, or corrugated metal)

Marking Stud Locations

Locate the studs on the exterior wall by either measuring from the interior wall or using standard framing layouts and building component reference points. Mark the stud locations on the siding with a carpenter's pencil. Verify the presence of a stud by drilling a small hole through the siding where the awning will be installed.

Cutting the Ledger and Fascia Boards

Use a miter saw to cut the ledger board and the fascia board to the desired length. The ledger board will be attached to the wall, while the fascia board will be the outward-facing vertical board on the opposite end.

Marking Rafter Layout

Determine the number of inside rafters you'll need by subtracting 1.5 inches from the ledger board length and dividing that figure by 24. Round this number to the nearest whole number. Then, find the distance between rafters by dividing the number of rafters by the ledger board length. Mark these distances on the ledger board with a tape measure and speed square. Transfer these marks to the fascia board using a framing square.

Cutting and Securing Rafters

Cut the rafters to length with a miter saw. Secure the rafters to the ledger board by holding them flush to the layout marks and driving two 3-inch structural screws into each. Repeat this process for the fascia board, attaching the other end of the rafters with two 3-inch screws.

Attaching the Ledger Board

Hold the ledger board against the wall, lining up the stud marks. Drill a 4-inch deep pilot hole through the ledger board and into the wall at each stud mark. Drive a 4-inch lag bolt into each pilot hole using an impact driver. Check that the ledger board is level, and adjust if necessary.

Creating Diagonal Braces

Measure the distance from the wall to the outside surface of the ledger board. Cut two braces with 45-degree angles at one end to match this measurement. Place the braces against the wall and the inside surface of the rafters, with the top end close to the fascia board. Mark, cut, and secure the braces with 2 1/2-inch structural screws through the brace into the rafter.

Attaching the Covering Material

Cut your chosen covering material to the dimensions of the awning. Secure it to the top of the frame, following the appropriate process for your material.

Your awning frame for your 66 Frolic camper is now complete! You can add extra aesthetic touches, such as filling in screw heads with wood filler and painting or staining the awning to match your camper. Enjoy your new shaded outdoor space!

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Attaching the awning to the camper

Attaching the awning to your 66 Frolic camper is a straightforward process, but it does require some careful planning and preparation. Here are the steps you can follow:

  • Plan the Attachment Method: Decide whether you want to attach the awning to the railing of your camper or drill into the body of the camper. If your camper has a railing, using it can be an easier option. If not, you may need to drill holes and attach mounting brackets to secure the awning.
  • Prepare the Awning Fabric: Measure the width and length of your camper to determine the size of the awning fabric you need. You can use a tarp or awning fabric, but make sure it is heavy-duty and durable. Fold or cut the fabric to the appropriate size, leaving enough room for grommets or attachment points.
  • Create Hanging Clips: You will need to create hanging clips or purchase canopy tie bungees to attach the awning to the camper. If you're making your own, you can use paracord or bungee cord with plastic balls at the end to hold the tarp in place. Slip the steel rods through the bungee cords and attach them to the grommets on the tarp.
  • Attach the Awning: Slip the hanging clips through the grommets on the tarp and then attach them to the railing or mounting brackets on your camper. Make sure to space them evenly and secure them tightly.
  • Add Support Poles: Depending on the design of your awning, you will need to add support poles to hold it up. These poles can be attached to the ground using stakes or attached to the body of the camper. Ensure the poles are sturdy and angled correctly to provide adequate support.
  • Secure with Bungee Cords: For added stability, use bungee cords to secure the bottom of the awning to the trailer or the top of the camper. This will help prevent the awning from moving or flapping in the wind.
  • Test and Adjust: Once the awning is attached, test it in different weather conditions to ensure it is secure. Make any necessary adjustments to the attachment points, support poles, or bungee cords to improve stability.

Remember to take accurate measurements, plan the attachment method carefully, and always follow safety guidelines when working with tools or equipment. With these steps, you should be able to successfully attach the awning to your 66 Frolic camper.

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Adjusting the awning for weather conditions

Adjusting the awning of your camper is crucial to ensure that it withstands various weather conditions. Here are some detailed instructions to help you adjust your awning accordingly:

  • When facing strong winds, heavy rain, or hail, it is important to retract your awning to prevent damage. Strong weather conditions can cause misalignment or even bend the awning arms.
  • If you notice any misalignment in the awning arms, carefully adjust the awning fabric by unscrewing it from the railing and moving it slightly. This will help you realign the arms with the railing. Make sure to do this gently, as the extended awning fabric will be under tension.
  • In the case of a wobbly awning arm, check the fitting between the motor and the outer bar of the awning. Tighten any loose screws you find, but be careful not to overtighten, as this can damage the material.
  • If the awning continues to wobble, inspect the arm mechanisms for any loose screws, as this could cause drooping.
  • For further stability, consider adding support poles or rafters to create a slight slope. This will also help prevent water from pooling on the awning fabric.
  • Regularly inspect your awning for any signs of wear and tear, such as tears or loose stitching. Clean the awning fabric with mild soap and water, avoiding harsh chemicals.
  • If you frequently camp in windy areas, invest in a sturdy and wind-resistant awning. Alternatively, for hot and sunny locations, choose an awning with UV protection to provide shade.
  • Ensure proper stability by anchoring the awning securely to the ground using stakes or weights. Avoid setting up in areas with loose soil or sandy surfaces, as they may not provide enough support.
  • Consider adding sidewalls or screens to your awning for extra protection from the elements. These can be easily attached using hooks or Velcro strips, providing additional shade, privacy, and protection from bugs and wind.
  • When not in use, always keep your awning clean and properly stored to prevent unnecessary wear and tear.

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Maintaining and repairing the awning

Maintaining and repairing your camper awning is crucial to ensure its longevity and avoid costly repairs. Here are some detailed tips to help you maintain and repair your camper awning:

Regular Cleaning and Inspection:

  • Clean your awning fabric regularly to prevent mould, mildew, and dirt buildup. Use cleaners specifically made for vinyl or your specific awning material.
  • Inspect the awning fabric, arms, tube, rail, lock pins, adjuster knob, torsion assemblies, and travel locks for any signs of wear, damage, or misalignment.
  • Look for holes, rips, thinning fabric, loose stitching, frayed edges, structural damage, bent or broken parts, and ensure all components are securely attached.

Retracting the Awning:

  • Always retract your awning during heavy rain, strong winds, or when not in use for extended periods.
  • Ensure the awning is completely dry before retracting to prevent mould and mildew growth.

Lubrication:

Lubricate moving parts like the awning tube and retractable arms with a silicone-based dry lubricant to ensure smooth operation and prevent rust and seize-ups.

UV Protection:

Consider applying a UV-resistant spray to your awning fabric to protect it from sun damage, which can weaken the material over time.

Repairing Tears and Holes:

  • For minor tears and holes, use awning repair tape or a tent repair kit to fix them. Ensure the area is clean and dry before applying the tape.
  • For larger tears and holes, you may need to replace the awning fabric. Cut a swatch of matching fabric, layer it over the damaged area, and adhere it with waterproof RV glue. Trim away any rough edges for a seamless finish.

Replacing Parts:

If any parts of your awning are damaged beyond repair, such as the knob adjuster, awning lift handle, mounting bracket, or spring assembly, replace them with new parts.

Electric Awning Precautions:

  • If you have an electric awning, regularly inspect the motor and wiring for any signs of damage or wear.
  • Keep the awning fabric clean and free from debris to prevent it from getting caught in the motor or causing electrical issues.

Seek Professional Help:

For major damage or complex repairs, consult a professional RV technician or dealer to ensure proper and safe repairs.

Frequently asked questions

You will need an awning rail, a tarp, and poles. You can also use suction pads, rope, and eyelets.

You can attach the awning to your camper using an awning rail, or by drilling holes and bolting the awning on. You can also use suction pads or VHB tape to avoid drilling into your camper.

You can attach the poles to the tarp by sewing on a piece that slides into the rail, or by using grommets.

You can use guy ropes to secure the awning to the ground. You can also use paracord to tie the awning to the top of your camper.

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