
Building a pop-up camper can be a fun project, but it requires a significant amount of time, money, and expertise. The process involves designing a suitable layout, selecting appropriate materials, and carefully constructing the various components. While some people opt for welding aluminium, others choose wood as their primary material. The choice of materials and design can impact the overall cost, with some people reporting expenses of around $4000 for parts alone. Additionally, it is important to consider the electrical, water, heating, and refrigeration systems required for a functional and comfortable camper.
Characteristics | Values |
---|---|
Materials | ACM paneling, wood frame, foam, fiberglass, epoxy, aluminium, very high bond (VHB) tape, polyurethane foam, fibreglass extrusions, aluminium composite panel, Baltic birch plywood, adhesive, aluminium extrusions, vinyl, aluminium studs, metal window frames, lithium batteries, wood, rubber, burly outdoor rug |
Time | 4 months of weekends |
Cost | $4,000 for parts, $7,000 to buy a pre-made camper, $10,000 for components and materials |
Weight | 400 lbs |
Time to build | 250 hours of labour |
Tools | Hole-saw bits, adhesive, pocket-hole jig |
Design | Folding wall system, ultralight, four-season, no-weld, slide-in, pop-up |
What You'll Learn
Choosing the right materials
Durability and Weather Resistance
Select materials that can withstand the elements, including rain, wind, and sunlight. For the exterior, consider using materials such as aluminium, fibreglass, or composite panels. Aluminium is lightweight, strong, and resistant to corrosion, making it a popular choice for pop-up campers. Fibreglass is another option that, when combined with polyurethane foam, creates a well-insulated and durable structure. Composite panels, such as those offered by Total Composites, provide excellent insulation and durability while being lightweight.
Weight Considerations
The weight of the materials you choose will impact the overall weight of your pop-up camper. Lighter materials, such as aluminium and fibreglass, can help keep the weight down, making it easier to transport and reducing the strain on your vehicle. However, it is also important to ensure that the materials are strong enough to support the structure and any additional features you plan to include.
Insulation
Insulation is crucial for maintaining a comfortable temperature inside your pop-up camper, especially if you plan to use it in cold weather. Look for materials with high R-values, which indicate better insulation properties. For example, the Total Composites camper mentioned above has R-12 insulation, which is significantly higher than the R-4 insulation found in many competitors. This will help prevent condensation and keep the interior comfortable, even in chilly conditions.
Ease of Construction
Consider your level of DIY expertise and the tools you have available when selecting materials. For example, while aluminium can be welded or riveted, it requires skill and the right equipment. Wood, such as plywood or spruce, may be easier to work with for beginners, as it can be cut and shaped with basic tools. Additionally, adhesives like construction-grade glue or very high bond (VHB) tape can be used to join some materials without the need for welding or riveting.
Cost
The cost of materials can vary significantly, so it's important to consider your budget when making selections. While some materials, like aluminium and composite panels, may be more expensive upfront, they can offer long-term savings by providing durability and customisation options. On the other hand, wood is generally more affordable but may require more maintenance and have a shorter lifespan.
Remember to research the specific materials you are considering and take into account any unique features or requirements of your pop-up camper build.
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Building a folding wall system
Choose the Right Materials:
Start by selecting high-quality, lightweight materials for your folding wall system. Wood, aluminum, or a combination of both can be used for the frame, ensuring it is sturdy enough to support the camper during transport and use. For the walls themselves, consider using a combination of a wood frame, foam insulation, and a lightweight exterior material such as fiberglass or epoxy. This will help reduce the overall weight of your camper while still providing solid walls.
Design and Planning:
Take precise measurements and create a detailed design plan for your folding wall system. Consider the number of walls, their dimensions, and how they will fold and unfold. CAD design software can be extremely useful for creating a digital model and visualizing the entire system before you start building. Don't forget to make a bill of materials (BOM) to ensure you have everything you need before you begin construction.
Hinge and Strut Selection:
Choose durable hinges that can handle the weight of your walls and allow for smooth folding and unfolding. Struts are also an important consideration, as they will provide the necessary support for your walls. Gas struts, in particular, can be a great choice for deploying the pop-up area with ease. Ensure you have the correct number and placement of struts to provide adequate support.
Assembly and Testing:
Build your folding wall system according to your design plans, paying close attention to detail. Take your time with the assembly, as this can be a complex process. Once the walls are built, thoroughly test their functionality. Ensure they fold and unfold smoothly and lock securely into place. Make any necessary adjustments until you achieve the desired result.
Waterproofing and Finishing:
To protect your folding wall system from the elements, consider waterproofing measures such as using vinyl glue or tape to seal seams and joints. Test your pop-up camper in various weather conditions to ensure that your folding wall system is durable and can withstand different environments. Finally, give your walls a smooth finish by sanding and painting them to your desired colour and style.
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Electrical and lighting systems
12-Volt DC vs. 120-Volt AC Power Systems:
- In the past, most pop-up campers used 12-volt DC systems, but nowadays, it is more common to use 120-volt AC power systems with power inverters.
- 12-volt DC systems power devices directly from a 12-volt battery, but they have limitations due to power losses during transmission, requiring thick and expensive wiring.
- 120-volt AC systems, on the other hand, use power inverters to convert 12-volt DC power from the battery into 120-volt AC power, also known as "house current."
- With a 120-volt AC system, you can use standard appliances and lighting fixtures from stores like K-Mart, which are more affordable and widely available than their 12-volt DC counterparts.
Power Inverters:
- When choosing a power inverter, opt for one with a continuous power output slightly higher than the total power draw of all the devices and lights you plan to run simultaneously.
- Follow the manufacturer's recommendations for wire size from the battery to the inverter to ensure efficient power transmission.
Battery Selection:
- For pop-up campers, a standard "marine deep cycle" battery is a good choice as it can withstand deeper discharge compared to car engine starting batteries.
- To ensure long battery life, avoid discharging the battery below 50% of its capacity. For occasional deeper discharges, a 30% discharge is acceptable, but this will reduce the battery's lifespan.
- The Trojan CB-27 battery is a suitable option, offering 100 amp-hours of power.
Lighting Choices:
- Incandescent light bulbs are inefficient and waste a lot of power as heat. Instead, opt for fluorescent (FL) or compact fluorescent (CF) bulbs, which are far more efficient and provide better value for money.
- LED lights are another option but are not as efficient as advertised and may be more expensive.
Solar Panels:
- Solar panels can provide a renewable energy source for your pop-up camper, but they need to be positioned in direct sunlight to maximise power output.
- Flexible solar panels are an option but are more expensive. A cost-effective alternative is to use a standard solar panel with single-crystalline or poly-crystalline cells embedded in fibreglass instead of glass to prevent breakage during transport.
- Ensure you use the proper wire size when connecting the solar panel to minimise power losses.
- Solar panel controllers are not necessary for standard "flooded lead-acid" batteries but are required for gel cell batteries.
Shore Power:
- Shore power, also known as "grid power," can be a useful supplement to your pop-up camper's electrical system when camping at sites with electrical hookups.
- You can use a simple 10-amp battery charger from an auto parts store to charge your battery while plugged into shore power.
Generators:
- Generators can be beneficial when camping off-grid without access to shore power. They can be used to boost your battery during the day and power appliances directly.
- Choose a generator that can handle a large battery charger to maximise efficiency.
Water Pressure:
- For water pressure, you can keep it simple with a standard camper-style water faucet. If shore water pressure is available, you can use it directly. Otherwise, a manual pump will suffice.
- Avoid electric water pumps as they add complexity and can be irritating if they fail due to low battery power.
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Plumbing and water systems
Freshwater Tanks
The size of the freshwater tank will depend on your daily water usage and how often you want to refill it. For example, if you use 1.5 gallons of water per day and want to refill every four days, you would need a 6-gallon tank. You can choose between portable containers and fixed tanks. Portable containers are easy to disconnect and refill, while fixed tanks can be installed inside or outside the van and typically hold more water.
Water Pumps
Water pumps draw water from the freshwater tank and pressurise the water system. There are two types of water pumps: electric and manual. Electric pumps, such as the Shurflo pump, operate on 12-volt DC power and provide strong flow rates. Manual pumps, like the Whale foot or hand pump, are cheaper and don't require power but may not deliver as much water.
Plumbing Pipes and Fittings
When choosing plumbing pipes, consider ease of installation, flexibility, and cost. PEX tubing is easy to work with and ideal for tight spaces, while PVC is cheaper but more challenging to install and not as flexible. Braided vinyl tubing is a durable and flexible option.
Various fittings are available for connecting the pipes, such as rubber ring gaskets, which create a watertight seal between male and female NPT fittings.
Hot Water Heaters
Hot water heaters are not necessary but can provide a more comfortable van life. Electric heaters, like the Bosch 2.5-gallon mini-tank, require a robust electrical system. Propane heaters, like the Camplux portable propane water heater, are compact and ideal for van conversions but require natural gas. Solar showers, like the Advanced Elements Solar Shower, are a great option if you want to avoid electricity or propane; they heat water using the sun or a camping stove.
Water Faucets and Sinks
When choosing a water faucet, consider the height and whether you want a single faucet or separate hot and cold water handles. Pull-down faucets with a hose make washing up more accessible. For sinks, consider the dimensions, height of the cabinet, layout, and whether you want an undermount or drop-in sink. Drop-in sinks are typically easier to install and less prone to mould and water retention issues.
Grey Water Tanks
Grey water tanks hold the dirty water from the sink and shower. To determine the size, consider your water usage rate and how often you want to dump the tank. Portable grey water tanks, like the Reliance 6-gallon container, are ideal for those who don't require daily water usage and can be dumped almost anywhere. Fixed grey water tanks can be installed inside or outside the van and typically offer more capacity.
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Heating and refrigeration systems
Heating and refrigeration are essential components of a pop-up camper, ensuring comfort and preserving perishables. Here is a detailed guide on selecting and installing these systems:
Heating System Options:
When choosing a heating system, consider factors such as function at altitude, fuel type, installation complexity, and budget. Here are some popular options:
- Gas or Diesel Air Heaters: These compact units are commonly used in camper vans. They connect to your fuel tank and require a small amount of 12V power. They produce hot air through a single output, with a range of 6,500 to 14,000 BTU. Installation involves drilling holes for fuel lines, routing power, and installing vents.
- Hydronic Heating Systems: These systems use heated coolant to provide hot air, hot water, and even heated floors. They are highly efficient, work at high altitudes, and have a higher heat output than air heaters. However, they are more complex to install and costlier, ranging from $4,000 to $6,000.
- Wood-Burning Stoves: These stoves use firewood to generate heat and are ideal for those who stay in one spot for extended periods. They require no power or fuel connections but need proper ventilation and regular firewood supply.
- Propane Heaters: Propane heaters, like the Propex HS2000, are suitable if you already have a propane system onboard for cooking or hot water. They have lower heat output but offer cleaner burns and easier maintenance.
- Mr. Buddy Heaters: These are budget-friendly interim solutions that require proper ventilation to prevent carbon monoxide buildup.
Refrigeration System Options:
For refrigeration, you can either engage professionals or opt for a DIY conversion. Consider the following:
- Conversion Companies: Specialists can efficiently convert your van, ensuring a worry-saving and quick process. Research and select a reputable company with experience converting your van model and meeting your specific requirements.
- DIY Conversion: If you have a standard full-size light commercial vehicle, you can add insulation and a refrigeration unit. This option reduces costs and allows you to customize the conversion. Guchen Thermo offers conversion kits and units suitable for various vehicles.
Installing a Refrigeration Unit:
The process typically involves two steps:
- Insulation: Add thermal insulation to the cargo area, including the floor surface, door skin, insulated panels, and liner coverings. Ensure the insulation panels follow the contours of your van's interior for a quality installation.
- Refrigeration Unit Installation: Choose a unit based on the desired transport temperature. For frozen cargo, select a freezer unit that can reach temperatures as low as -30°C. Consider the power source, such as vehicle engine-driven units or DC-powered electric units for smaller vans. Follow the supplier's installation instructions, ensuring proper ventilation and power management.
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Frequently asked questions
You will need a utility trailer frame, plywood, spruce wood, aluminium sheet, a tent, a mattress, hinges, car scissor jacks, and a door. You will also need tools such as a crank handle, extension bar, or electric lifter system.
The frame can be built from a mixture of materials and wood products. For example, you can use pressure-treated plywood and spruce for the trailer bed, side walls, and railing. You can also use aluminium sheet to cover the unit.
It is important to find a level site, disconnect from your tow vehicle, level and stabilize your camper, and check for any low-hanging branches or obstructions. You should also disconnect the roof from the camper's body and use a crank handle, extension bar, or electric lifter system to extend the roof.