Building Sturdy Pop-Up Camper Sides

how to make hard sides for a pop up camper

If you're looking to make hard sides for a pop-up camper, you're not alone. Many people have considered converting their pop-up campers to hard-sided campers, and some have even shared their experiences online. There are several reasons why you might want to make this conversion. Firstly, new hard-sided campers can be expensive, often costing more than $10,000. Secondly, adding hard sides can make your camper sturdier and more weatherproof, providing better protection against the cold, winds, rain, snow, and ice. Finally, it can be a fun project for those who are handy and enjoy do-it-yourself projects.

However, there are also some disadvantages to consider. Adding hard sides will increase the weight of your camper, which can affect fuel efficiency when towing and may push the limits of your current tow vehicle. Additionally, the higher profile of the camper can make it more difficult to travel with. Before making the conversion, it's important to consider the weight limitations of your camper's frame and the complexity of the build, especially if you want to keep the pop-outs.

There are different styles of hard-sided pop-up campers to choose from, such as the Alaskan Style, Hiatus Style, and Oru Designs, each with its own advantages and disadvantages in terms of height, complexity, and cost. The process of converting a pop-up camper to a hard-sided camper involves framing the sides, cutting out windows and doors, adding insulation, and finishing the walls with materials like plywood, vinyl, or aluminum siding. It's important to consider the weight and durability of the materials used and ensure that the camper still collapses for transport if desired.

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Framing the side-outs

When creating the frame, it is crucial to select materials that provide the necessary strength while keeping weight to a minimum. While wood is a common choice, it is important to consider lighter alternatives such as aluminum framing materials. This is especially important if you plan to keep the maximum space provided by the side-outs, as a more intricate framing process will be required to support the weight.

Once the framework is in place, a plywood base can be added to the walls. Plywood provides a sturdy structure for insulation and exterior siding, as well as some insulation itself. It is available in different thicknesses, allowing you to choose an option that minimises weight while still providing the necessary stability.

Before moving on to insulation and siding, it is important to cut out any openings for windows, doors, vents, or other access points. This ensures that insulation can be installed efficiently without having to work around these openings.

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Cutting out windows and doors

First, you need to decide on the placement of your windows and doors. Consider the interior layout of your camper and mark the areas that need to be cut. It is important to be precise during this step as inaccurate markings can lead to an ill-fitting window or door.

Once you have marked the areas, use a drill to create a series of holes along the edges of the marked areas. These holes will help you transfer the markings to the other side of the camper. Drill enough holes to ensure that the markings are accurately transferred.

After transferring the markings, you can start cutting. Using tools like a nibbler, jigsaw, angle grinder with a cutting disc, or a hacksaw, carefully cut along the marked areas. This process can be tricky, especially around corners and across supporting struts. Take your time and go slow to ensure a precise cut.

If there are any strengthening beams or struts in the way, you may need to cut through them separately using an appropriate tool, such as an angle grinder, jigsaw, or hacksaw. Be cautious not to cut through any structural pillars or supports that are crucial to the integrity of the camper.

Once the cutting is complete, use a metal file to smooth out any rough edges and remove any sharp burrs. This step is important for both safety and aesthetic reasons. After filing, apply a rust-proof paint to the edges to prevent corrosion.

Before installing the windows and doors, it is essential to prepare the cut-out areas properly. Vacuum or clean the area thoroughly to remove any metal shavings or debris. These can cause rust if left unattended.

Now, you can install the windows and doors. Follow the manufacturer's instructions for the specific type of window or door you have purchased. Ensure that the windows and doors are securely fitted and sealed to prevent leaks and ensure insulation.

Finally, test the functionality of your newly installed windows and doors. Open and close them a few times to ensure smooth operation. Check for any gaps or leaks, and make adjustments as necessary.

Converting a pop-up camper to a hard-sided one by adding windows and doors can be a challenging task, but with careful planning and execution, it can be a rewarding project that adds comfort and protection to your camper.

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Temporary or permanent hard sides

One of the first things you have to decide when considering adding hard sides to your pop-up camper is whether you want your hard sides to be temporary or permanent. This decision will affect the rest of the build.

Temporary Hard Sides

If you want to have temporary hard sides, you will need to create a design that allows for the soft sides to remain intact when removing the hard sides. Alternatively, your design will need to incorporate foldable hard sides that can collapse when closing the pop-up.

Permanent Hard Sides

Permanent hard sides are generally easier to construct. You can work off of the current layout of your pop-up camper to give you a guide to a simple framework, and then attach the sides. Once you decide on your layout and refine your plans, you can start the build.

Materials

First, you will need to build a frame to which you can attach walls and siding. Consider the materials and weight of your frame. You may think of wood as the go-to material, but you can also use aluminium framing materials and other options that have all the necessary strength at a fraction of the weight of wood.

Weight Considerations

Crucially, you must know your pop-up camper's gross vehicle weight rating (GVWR) for the frame. This is the total weight the structure can hold when fully loaded, including supplies and people. Surpassing the GVWR can compromise the structure's integrity and cause dangerous driving conditions when towing.

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Keeping or removing pop-outs

Keeping or removing the pop-outs of your pop-up camper is one of the first things you should consider when thinking about adding hard sides. Many pop-up campers have beds or seating areas on the ends that pop out, adding living space when the camper is set up.

If you decide to keep the pop-outs, you can still do so, but it adds another layer of complexity to the build. Keeping the maximum space that pop-outs or side-outs provide requires a more involved framing process. You will need to be diligent in your planning and consider how the frame will support the weight of the side-outs.

If you remove the pop-outs, you will have a simpler build and a sturdier structure. However, you will lose the extra space that the pop-outs provide.

Another option is to create a design that allows for the soft sides to remain intact when removing the hard sides. Or you can design foldable hard sides that can collapse when closing the pop-up.

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Weight capacity of the camper frame

When considering adding hard sides to a pop-up camper, it is crucial to determine the weight capacity of the camper frame, also known as the gross vehicle weight rating (GVWR). This rating indicates the maximum weight that the camper's structure can safely hold when fully loaded. Surpassing the GVWR can compromise the structural integrity of the camper and create dangerous towing conditions.

To ensure safety and maintain structural integrity, it is essential to consider the weight of the added hard sides, as well as the weight of people and belongings that will be accommodated in the camper. The weight of the camper's features, such as air conditioning, awning, water heater, and other amenities, should also be factored in when calculating the total weight.

The weight capacity of the camper frame will depend on the specific model and design of the pop-up camper. Larger pop-up campers with more amenities can weigh over 2,000 pounds, while more basic models weigh around 600 pounds empty. When adding hard sides, it is important to choose lightweight materials such as aluminium framing and siding, or plywood of varying thicknesses, to minimise the added weight.

It is also worth noting that the weight of the camper affects the choice of tow vehicle and fuel efficiency. A heavier camper will require a larger tow vehicle and will result in lower fuel efficiency. Therefore, it is crucial to strike a balance between the weight of the camper and the capabilities of the tow vehicle to ensure safe and efficient travel.

Additionally, it is recommended to have trailer brakes installed for campers weighing more than 2,500 pounds, and it is mandatory for campers over 3,000 pounds. This adds an extra safety measure and improves control during towing.

Frequently asked questions

The main benefit of putting hard sides on a pop-up camper is that it makes the camper sturdier and more weatherproof. It also offers additional comforts and protection that tent camping does not, such as a kitchenette, electric hookups, a toilet, and a real door.

The main disadvantages of putting hard sides on a pop-up camper are losing its low profile and ease of travel. It will likely weigh more than when it had soft sides, which could push the limits of your current tow vehicle. The higher profile and weight of the camper will also lower fuel efficiency when towing it.

You need to consider whether you want the hard sides to be temporary or permanent, keeping the pop-outs or not, and if the frame can safely handle the weight of a hard-sided build. You must also know your pop-up camper's gross vehicle weight rating (GVWR) to ensure that the structure can hold the weight when fully loaded.

The process involves framing the side-outs, cutting out any windows or doors, building a frame for the walls, considering materials and weight, adding a plywood base, insulating, and finishing the walls.

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