Diy Hydraulics For Pop-Up Campers: A Step-By-Step Guide

If you're looking to make hydraulic lift systems for your pop-up camper, there are a few options to consider. You could opt for a hydraulic lift system, which can be expensive to implement, or choose an electric winch, which is the next best alternative. Coleman did offer a hydraulic lift system, and you can find information on it online. Additionally, there are power lift systems available for Goshen and similar campers that use a single main lift cable. If you're handy, you could even attempt to fabricate your own system by mounting an electric winch to the rear of the camper.

Using a winch system

Choosing the Right Winch

First, you'll need to select an appropriate winch for your pop-up camper. There are two main types to consider: manual and electric. A manual winch will require you to crank the handle by hand, while an electric winch will do the work for you with the push of a button. If you opt for an electric winch, make sure to choose one that can power load both in and out, so you can raise and lower your camper without any hassle.

Installation Process

Once you've selected your winch, it's time to install it. If you're handy with tools, you may be able to do this yourself, but if not, consider seeking professional assistance. The installation process will vary depending on the make and model of your camper and the type of winch you choose. However, here are some general steps to give you an idea:

• Prepare the Winch: Read the instructions that come with your winch carefully. You may need to assemble certain parts or make adjustments to ensure it fits your camper.
• Mount the Winch: Identify a suitable location for your winch on your camper. This is usually at the front tongue of the camper, but refer to your specific camper's instructions. Securely mount the winch according to the manufacturer's guidelines.
• Connect the Cables: The winch will have a cable that needs to be connected to the camper's lift system. This may involve removing the existing manual crank system and replacing it with the winch cable. Ensure all connections are tight and secure.
• Test the Setup: Once everything is connected, test the winch to ensure it's functioning properly. Raise and lower the camper slowly and observe if there are any obstructions or issues. Make any necessary adjustments to ensure smooth operation.
• Maintain the Winch: Regular maintenance is crucial to keep your winch in good condition. This includes lubricating moving parts, checking for wear and tear, and ensuring that all connections are tight. Refer to your winch's user manual for specific maintenance instructions.

Additional Considerations:

• Safety: Always prioritize safety when working with winches and pop-up campers. Ensure that the winch is securely mounted and that all connections are tight to prevent accidents. When raising or lowering the camper, be cautious and follow any safety guidelines provided by the manufacturer.
• Weight Capacity: Ensure that your winch has sufficient capacity to handle the weight of your pop-up camper. Check the weight of your camper and choose a winch with a higher capacity to ensure it can handle the load.
• Power Source: If you opt for an electric winch, consider the power source. You may need to connect it to your camper's battery or another power supply. Ensure that all electrical connections are secure and insulated to prevent short circuits.
• Limit Switches: Some winches have limit switches that control how high or low the camper can be raised or lowered. Adjust these switches according to your preferences, ensuring that the camper stops at the desired height.

By following these steps and considerations, you'll be well on your way to enjoying a hassle-free pop-up camper experience with the convenience of a winch system.

Manual vs. electric systems

Manual lift systems for pop-up campers can be cumbersome and time-consuming to operate, especially for older campers. They may also be difficult to use for those who are less physically able. Manual systems can also be prone to damage from rust caused by wet weather, and may not be sturdy or well-crafted.

Electric lift systems, on the other hand, can save time and energy. They are also easy to operate and can lift heavier weights than manual systems. The Goshen lift system, for example, is found on the majority of pop-up campers and can be powered by a 12-volt battery. The Roof Jenie Hydraulic Lift System is designed to work with the Goshen system and costs around $448, depending on the version.

The process of converting a manual lift system to an electric one is relatively straightforward and can be done yourself. It involves removing the old crank and handle system, installing an electric winch/motor in its place, and hooking up the existing cables and mechanism to the new motor.

There are a variety of electric lift systems available, including the Powerwinch 1200lb Lift System and the Round and Square Drive Lift Motors. It is important to ensure proper maintenance of the lift system, regardless of whether it is manual or electric, to avoid malfunctions and potential accidents.

Pneumatic vs. hydraulic systems

Pneumatic and hydraulic systems have many similarities. Both use fluid power, with a pump as an actuator, and are controlled by valves. However, there are some key differences between the two systems. Pneumatic systems use compressed gas (usually air) to generate power, while hydraulic systems use relatively incompressible liquids such as oil or water. This distinction leads to several advantages and disadvantages for each system.

Pneumatic systems are generally simpler in design and have lower initial costs than hydraulic systems. They are also easier to maintain, as they are powered by compressed air, which is easy to obtain and store. Pneumatic systems are commonly used in construction, robotics, food manufacturing, medical applications, and factories. They are ideal for applications that require no risk of contamination, such as in the food and pharmaceutical industries, as they provide a clean and dry environment. Additionally, pneumatic systems are safer than hydraulic systems, as there is little chance of fire or explosion due to the use of compressed air.

On the other hand, hydraulic systems are more powerful and capable of moving heavier loads. They operate at higher pressures, typically 1500-2500 psi, and can generate higher forces from small-scale actuators. Hydraulic systems are often used in heavy equipment, such as excavators, hydraulic presses, and aircraft wing flaps. They are also applied in everyday machines, such as car braking systems and wheelchair lifts. However, hydraulic systems are generally larger and more complex, requiring more space and pressure. They also have higher initial costs due to the need for a power unit.

When deciding between a pneumatic or hydraulic system for a pop-up camper, several factors should be considered. Pneumatic systems are simpler, more cost-effective, and safer, while hydraulic systems are more powerful and capable of lifting heavier loads. The specific requirements of the camper, such as the weight of the roof and the desired speed of operation, will determine which system is more suitable. Additionally, the availability of resources and the level of maintenance required may influence the decision.

Repairing a hydraulic brake system

While there is little information on how to make hydraulics on a pop-up camper, I can provide a detailed, step-by-step guide on repairing a hydraulic brake system.

Step 1: Kit Required

Firstly, you must obtain a kit for MTB hydraulic brakes. Depending on the model of the brakes, the kit may differ slightly. In general, it will consist of two syringes (or a syringe and a cup) with tubes that have a connection for purge sites, brake circuit oil (mineral or DOT, depending on the model), and one or more wrenches.

Step 2: Purge Preparation

Place the bike on a stand that keeps it stable and correctly inclined, depending on whether the braking circuit is in the front or the rear. A right angle keeps the circuit tube vertical, making it easier to eject air bubbles. Loosen the brake lever and move it to the horizontal position, along with the small oil tank to which it is connected. Loosen the brake caliper and disconnect it from the frame. Remove the pads and insert a "bleed-block" inside the clamp, which is a plastic spacer that keeps the pistons pressed outwards. Loosen and remove the two purge nipples present on the caliper and on the brake lever block. If there is any resistance from the screws, use some WD-40 Multi-Use to help.

Step 3: Syringe Connections

Insert the tubes with the threaded connection on the two syringes, removing the plunger from one of them. Screw this, through the tube and screw fitting, onto the brake lever bleed hole. With the syringe fitted with a plunger, draw in the new oil for the braking system, filling it three-quarters full. Then screw this purge tube onto the brake caliper. Some brake models have a special cup that screws onto the brake lever drain hole instead of a syringe without a plunger.

Step 4: Oil Injection

After loosening the "tap" of the caliper bleed by a quarter turn, slowly press on the syringe plunger with the new oil, connected to the brake clamp, to inject it into the braking circuit. As new oil is inserted, the old oil inside the braking circuit is ejected from the purge on the brake lever block and fills the upper syringe (which must be kept vertical). If a cup is present, it will fill up instead.

Step 5: Elimination of Air Bubbles

While injecting the oil, or at the end of the process, gently tap on the hose of the braking system to help air bubbles escape. Another effective method is to inject a small amount of oil into the upper syringe and, before injecting oil with the lower syringe, draw some oil from the circuit by pushing the plunger. This will suck the air from the circuit, releasing it into the lower syringe.

Step 6: Close the Circuit

Once the new oil has replaced the

Telescoping legs for support

Telescoping legs are a great way to support your pop-up camper and ensure it remains stable and level. They are also useful for levelling out your RV or camper van when parked on uneven ground.

There are a variety of telescoping legs available on the market, which differ in terms of their weight capacity, adjustability, and mounting style. When choosing a set of telescoping legs, it is important to consider the weight of your camper and the amount of levelling required.

Some telescoping legs come with a set weight capacity, typically ranging from 1000 lbs to 7500 lbs per leg. It is important to ensure that the combined weight capacity of the legs is sufficient to support the weight of your camper.

In terms of adjustability, telescoping legs typically offer a range of height adjustments to accommodate different levelling needs. This can range from as little as 11 inches to as much as 48 inches in height.

Mounting styles for telescoping legs can vary as well. Some legs are designed to be mounted directly to the frame of the camper, while others may be designed to attach to the camper's table or other furniture. It is important to ensure that the legs you choose are compatible with your camper's mounting options.

• Trailer Stabilizer Jacks: These telescoping legs typically offer a weight capacity of 1000 lbs each and can be adjusted from 12 inches to 18 inches in height. They are designed to stabilize and level your camper, reducing wobble and ensuring a safe and comfortable stay.
• RV Table Legs: These telescoping legs are designed to provide support and stability for your RV table. They are typically adjustable in height, ranging from 22 inches to 36 inches, and are made of durable materials such as aluminium alloy or stainless steel.
• Camper Stabilizer Jacks: These telescoping legs are designed specifically for pop-up campers and offer a higher weight capacity, typically around 5000 lbs. They help to stabilize and level your camper, ensuring a safe and comfortable camping experience.

When installing telescoping legs, it is important to follow the manufacturer's instructions and ensure that they are securely mounted to your camper. Additionally, regular maintenance and inspection of the legs and mounting hardware are crucial to ensure their longevity and safety.

Frequently asked questions