Rebuilding Truck Campers: Back-End Restoration Guide

Renovating a truck camper can be a challenging but rewarding project. Whether it's a pop-up or a hard-sided camper, there are several steps to rebuilding the back of a truck camper. Firstly, it's essential to assess the condition of the camper and identify any issues such as water damage, rot, or electrical problems. This may involve removing panelling and insulation to inspect the structure thoroughly. Once the necessary repairs have been made, the next step is rebuilding. This could include framing, insulation, electrical and plumbing work, and installing new appliances and fixtures. It's important to prioritise water resistance to prevent future damage. Finally, the interior and exterior of the camper can be customised with paint, cabinets, and accessories to create a comfortable and functional space. While renovating a truck camper can be a complex and time-consuming process, the end result is a unique and personalised space for exploration and adventure.

Removing and replacing rot and water damage

Identify the Damage

Before starting the repair work, it is crucial to identify the extent of the damage. Water damage and rot can be deceptive, so inspect every corner of the camper thoroughly. Check for soft spots, de-lamination, and any signs of water intrusion. Pay close attention to areas like seams, windows, and the roof, as these are common entry points for water. It is also essential to address any leaks that may have caused the wood rot, as neglecting them could lead to recurring issues.

Disassemble and Assess

Once you have identified the damaged areas, it is time to disassemble the affected parts of the camper. Remove screws, trim, and any other components that provide access to the damaged wood. Take pictures during this process to help with reassembly later. After exposing the damaged wood, assess whether it can be patched or if a more extensive replacement is needed. If the damage is limited to a specific area, you may only need to cut out and replace that section. However, if the rot is widespread, consider replacing the entire affected panel.

Remove the Damaged Wood

Using the appropriate tools, carefully remove the rotted wood. This process may involve cutting, drilling, and prying, depending on the location and severity of the damage. Be cautious not to cause further damage to the surrounding structures. Once the rotted wood is removed, clean the area thoroughly to eliminate any debris, dirt, or remaining wood fragments.

Prepare the Replacement Wood

Cut a new piece of wood to match the dimensions of the area you removed. Treat the new wood with a sealant, such as Flex Seal, to protect it from future water damage. You can also use a mould and mildew treatment for added protection. It is essential to ensure that the new wood is properly sized and treated to prevent future issues.

Install the Replacement Wood

Position the new piece of wood in the prepared area and secure it using appropriate fasteners, such as screws or staples. Ensure that all seams and joints are properly sealed with caulk or butyl tape to prevent future water intrusion. Reattach any trim, lights, or other components that you had previously removed.

Final Touches

After the wood replacement is complete, take the time to inspect your work and ensure that everything is securely fastened and sealed. Test the camper for any remaining leaks and address them promptly. You may also need to reapply paint or finish to the repaired areas to match the surrounding surfaces.

Remember that repairing water damage and rot can be a complex and time-consuming process, so don't hesitate to seek help from a professional or an experienced friend if needed. Taking your time and paying attention to detail will ensure a successful repair that will extend the life of your truck camper.

Installing a new electrical system

Planning:

Before you begin, it is crucial to understand your power needs. Make a list of all the electrical devices you plan to use in your camper, such as lights, fans, fridge, etc. Calculate the total power consumption by considering how much power each device uses and how often you will use them. This will help you determine the size and number of batteries you need.

Upgrading the Wiring:

The wiring that comes with your truck for a trailer connection is typically too thin to handle the power needs of your camper. Upgrade the wiring to at least 6AWG wire, and preferably 2AWG welding cables, to ensure it can handle higher power loads without overheating. Copper wire is a good choice, but it can be expensive. When routing the wires, be careful to avoid any sharp edges or moving parts that could damage the insulation.

Installing Breakers:

Install a breaker at both ends of the positive wire to protect the wire and yourself in case of a short circuit. A breaker also serves as a convenient switch to disconnect power during maintenance. A 100A Blue Sea 285 breaker is a good option.

Connecting to the Camper Battery:

Drill a hole in the wooden floor pack of your camper to route the wires to the battery box. Seal the hole with urethane caulk or butyl rubber tape to prevent moisture ingress. Install another 100A breaker just before the wires connect to the camper battery to provide additional protection.

Choosing the Right Battery:

There are two main types of batteries to consider: AGM (Absorbent Glass Mat) and LiFePo4 (Lithium-ion). AGM batteries are cheaper and widely available, but they have a shorter lifespan and require more frequent replacements. LiFePo4 batteries are more expensive but offer higher capacity and longer lifespans, making them a better long-term investment.

Adding a DC-DC Charger:

If you plan to charge your camper battery from your truck, consider installing a DC-DC charger. This device regulates the charging current to prevent overloading your camper battery. Choose a charger that is compatible with your battery type and ensure it is installed near the battery for maximum efficiency.

Solar Power Option:

If you want to incorporate solar power, install a solar panel on the roof of your camper. Calculate the size of the solar panel and the number of panels needed based on your power requirements and the amount of sunlight you expect to receive. Connect the solar panels to a solar charge controller, which regulates the voltage and current going into your batteries.

Monitoring and Maintenance:

Install a battery monitoring system, such as the Victron BMV series, to keep track of your battery's health and state of charge. LiFePo4 batteries have built-in protections, including a Battery Management System (BMS), which helps maintain the battery's lifespan. Always follow best practices for battery care, such as avoiding extreme temperatures and deep discharges.

Shore Power Option:

If you plan to use shore power at campgrounds, install a surge protector or an EMS (Electrical Management System) to protect your electrical system from power surges or faulty wiring. Connect the shore power to a battery charger to recharge your batteries while plugged into an external power source.

Remember to consult a professional or a qualified electrician if you are unsure about any part of the process. Electrical work can be dangerous if not done correctly, so always prioritize safety.

Building a new cabinet system

Planning and Design

Start by assessing the available space and deciding on the desired layout. Consider the appliances, storage needs, and any specific requirements you may have. Measure the available space accurately and create a scale drawing or digital model if possible. This will help visualise the cabinet system and make informed decisions about its design.

Materials and Tools

Select appropriate materials for the cabinet construction, considering factors such as durability, weight, and ease of installation. Plywood is a common choice due to its strength and versatility, but other options like lightweight composites or metal can also be considered. Ensure you have all the necessary tools, including power tools, hand tools, and safety equipment, before beginning construction.

Cabinet Construction

Build the cabinet boxes using the selected materials, cutting the components to size and assembling them securely. Utilise wood glue, screws, and brackets as needed to ensure sturdy construction. If you're working with metal, welding or riveting may be required. Consider adding features like soft-close hinges, drawer slides, and cabinet doors or fronts that match the overall design of your truck camper.

Installation and Finishing

Install the constructed cabinets into your truck camper, ensuring they are securely fastened and level. Fill any gaps with appropriate fillers or caulking, and consider adding trim or moulding for a seamless finish. Paint or stain the cabinets to match the interior of your truck camper, and don't forget to add cabinet knobs, pulls, or handles for easy access.

Customisation and Accessories

Depending on your specific needs, you can customise your cabinet system further. For example, you can add pull-out shelves, built-in lighting, or custom dividers to organise your items efficiently. Think about how you will use the cabinets and incorporate any additional features that enhance their functionality and aesthetics.

Removing and replacing the AC unit

The rear-mounted AC unit was removed to make way for the construction of a new wall. This process is relatively straightforward and can be done by following these steps:

Step 1: Removing the AC Unit

First, remove the plastic cover on the inside of the camper by unscrewing it. This will expose the electrical connection for the air conditioner. Ensure that the breaker for the air conditioner is turned off before disconnecting the wire harness to avoid any accidents. Then, remove the outer decorative plastic cover on the roof, which is usually secured with a few screws. With these covers removed, the main evaporator and condensing unit can be accessed.

Next, remove the hardware that connects the AC unit to the roof. This typically consists of four large bolts and nuts. With the hardware removed, use a putty knife or a Wonder Bar to pry loose the caulk and/or butyl tape that creates a watertight seal for the air conditioner.

Step 2: Lowering the AC Unit

After the AC unit is freed from the roof, carefully lower it with the help of a partner or friend. Be cautious to avoid injuring yourself, your partner, or damaging the roof of the camper.

Step 3: Roof Preparation

Preparing the roof for the installation of a new AC unit or a roof patch is crucial to ensure a watertight seal. Clean the roof of all debris and dirt. Use a light dish soap solution, a brush, and some elbow grease to wash the roof thoroughly. Allow the roof to dry completely before proceeding to the next step.

Step 4: Cutting the Metal Roof Patch

For this step, use a thick piece of aluminum or steel, which provides strength and lightweight support for the weight of a person standing on it. Measure the roof opening, adding an extra two inches on each side for overlap on the roof to accommodate the caulk. Cut two pieces, one for the roof and one for the inside of the camper.

Use a jigsaw with a fine saw blade designed for cutting metal to cut the metal, then smooth the edges with a file or grinder. Ensure that there is solid framing to screw into; if new framing is needed, install it now.

Step 5: Installing the Metal Roof Patch

With the roof clean, dry, and the metal cut to size, it's time to install the roof patch. Use a combination of caulk, butyl tape, and sheet metal roof screws to secure the patch. Apply Vulkem 116 to caulk the edges and screw heads for a watertight seal.

Install the metal patch on the inside of the camper, along with some insulation and a few screws, to complete this step. Seal your roof patch with a quality roof sealant once the caulk has dried.

Reinstalling the AC Unit

To reinstall the AC unit, follow the above steps in reverse. Ensure that the gasket on the bottom of the unit is intact and securely attached. Center the unit over the AC opening on the roof, making final adjustments from inside the camper. Reconnect the wiring harnesses and metal covering, then reattach the faceplate and grill insert.

On the roof, reattach the AC covering, centering it over the unit and screwing it into place.

Repairing holes in the wall

If you're repairing holes in the wall of your truck camper, the first step is to assess the damage. Are the holes small, large, or a mix of both? Are they caused by water damage or something else? Knowing the extent of the damage will help determine the best course of action for repairs.

If the holes are caused by water damage, it's important to address the underlying issue first. Check for any leaks in the roof, windows, plumbing, or exterior of the camper. Seal up any gaps or cracks that could be letting water in.

Once the source of the water damage has been addressed, it's time to start repairing the holes. For small holes, a product like JB Weld Water Weld Epoxy Putty can be used to fill them in. This putty is waterproof, paintable, and sets up quickly. Simply mix a small amount of the putty with your fingers and apply it to the hole, smoothing it out as much as possible. Once it's dry, you can sand it down for a smoother finish.

For larger holes, a product like Bondo can be used. Bondo is a messier option and has a strong smell, but it creates a nice, smooth finish. It comes in stranded and non-stranded varieties; the non-stranded option is less messy and easier to apply. Be sure to follow the instructions for mixing and application, as they can be a bit tricky. Once the Bondo has cured, you can sand it down for a smoother finish.

If there are very large holes that need backing, you can use a Bondo self-adhesive patch or a scrap of sheet metal glued to the backside of the hole. In some cases, you may need to remove the entire wall panel and replace it with a new one. This is a more labour-intensive and costly option, but it may be necessary for more extensive damage.

During the repair process, it's important to wear gloves and a mask to protect your hands and lungs from any chemicals or mould that may be present. Take your time and work in small sections to ensure a thorough repair. With the right tools and patience, you can have your truck camper's walls looking like new again!

Frequently asked questions