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off road camper build
- Thread starter joe lane
- Start date
hi all.
thanks cwc.
right camper build,
plenty of storage, kinda looking forward to getting the sewing machine out
i know things are going to rattle around so i have to look in to what i am storing shouldnt be a problem,
the next stage now is to close up the front, i still haven't secured a window or a skylight as im unsure, will the roof light leak on the 45 degree angle at the front, so im looking at a boat hatch, these are usually made from clear/coloured plastic and will not leak, and some are secured from the inside, so the search is on.
we have used the same timber as the roof as i wanted a bit of strength and a possible fix for anything i sit on the front a frame
this is a handy tool a laser line, loads of uses, in this pics it was used to line up the screw heads
now we cant do any more to the front till i get the window/s so its clean up time and turn the camper around, now i might get a chance to hitch it up to the truck, next pics should be interesting
well thats all for tonight so catch you all later, well im going to update my other build.
thanks cwc.
right camper build,
plenty of storage, kinda looking forward to getting the sewing machine out
i know things are going to rattle around so i have to look in to what i am storing shouldnt be a problem,
the next stage now is to close up the front, i still haven't secured a window or a skylight as im unsure, will the roof light leak on the 45 degree angle at the front, so im looking at a boat hatch, these are usually made from clear/coloured plastic and will not leak, and some are secured from the inside, so the search is on.
we have used the same timber as the roof as i wanted a bit of strength and a possible fix for anything i sit on the front a frame
this is a handy tool a laser line, loads of uses, in this pics it was used to line up the screw heads
now we cant do any more to the front till i get the window/s so its clean up time and turn the camper around, now i might get a chance to hitch it up to the truck, next pics should be interesting
well thats all for tonight so catch you all later, well im going to update my other build.
If you havent been there yet, IH8MUD has a cracking trailer tech section if you need any more ideas or inspiration 
good evening gentlemen,
thanks for the link gav peter
yes grant, can post the finished pics if you want but i think that will spoil it for every one,
right, well i had the pleasure to remove the said camper from the garage this evening, have some pics for you to look at, let me know what you think ?
in one of the pics you will see my son he is 6ft 3" so you have a general idea to scale
i think we got the size spot on, i can sit in the truck and see down both sides using the mirrors, its wider than its taller if you know what i mean
i love it, i need to adjust the brakes, the hitch was solid no rattles when braking,
right thats all for tonight catch you all later
thanks for the link gav peter
yes grant, can post the finished pics if you want but i think that will spoil it for every one,
right, well i had the pleasure to remove the said camper from the garage this evening, have some pics for you to look at, let me know what you think ?
in one of the pics you will see my son he is 6ft 3" so you have a general idea to scale
i think we got the size spot on, i can sit in the truck and see down both sides using the mirrors, its wider than its taller if you know what i mean
i love it, i need to adjust the brakes, the hitch was solid no rattles when braking,
right thats all for tonight catch you all later
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hi all,
gav no mate wont spoil it, im right up to date
right, with the camper back in the garage, it was time to start on the rear kitchen door, we have discussed this part to some end, and decided that a door that opens upward in true tear drop style will have another benefit, i can used the roof above my head as a frame for an awning, two poles that hold the door up will be the corner posts giving me an area of about 1.5 x 1.8 and what ever the roof finishes at
im trailing a new hinge at the moment its made of extrusion plastic with a rubber strip fixed at the centre, has been tested at 50,000 cycles and can carry 150kg over 1m length so should its well within my specs
any way some pics
we have cut the hinge like this so we get an overlap on to the sides, we can seal this with a p seal
im not taking any chances so we drilled/countersunk out the hinge every 100mm, then applied sika stickaflex
the ally piece you can see is a spacer, the bottom sheet is fitted under the lip on the hinge, the top sheet that comes over the top overlaps the top part of the hinge, it just to guarantee our seal
we cant build this on the bench as we want a custom fit to our rear, and this can only be achieved instu, we have packed out both sides to about 5mm and hung the top timber on the hinge and well here is the pics
the ply profile is the door ends so to speak we can afford to screw through here as the heads will not be seen
i have missed a few pics here in my hast, basically we fitted the bottom timber the filled in the rest, a couple of the timber had to be cut at 45 degrees as one is need on the upper corner and the one below which ties into the floor
the hinge works as it should but we keep testing to see if there is any bind
we use plenty of stickaflex here as were not using any fixings, we then rub stikaflex into the edges to seal ply
then fix the first sheet,
im using .9 ally sheet here, the blue colour is the protective coating, only costs a couple of pence, helps in a tight garage
i have only glued the top half as i have to bend the lower half manually when the glue goes off, its just a lot easier, keeps flex to a minimum,
this is the top sheet folded over 70mm and we have a 10mm overlap over top of the hinge, this bend had to be spot on as an deviation here throws it out on the opposite end of the sheet, should have took a pic i had 8 g clamps lined up for the bending
i took the rear door off today and finished the bending, i know its short, but i have an 80mm drip strip to fit and clean it up
thats the front end glued , again only up to the first bend,
back to work on monday so things will be going a bit slower now,
catch you all later
gav no mate wont spoil it, im right up to date
right, with the camper back in the garage, it was time to start on the rear kitchen door, we have discussed this part to some end, and decided that a door that opens upward in true tear drop style will have another benefit, i can used the roof above my head as a frame for an awning, two poles that hold the door up will be the corner posts giving me an area of about 1.5 x 1.8 and what ever the roof finishes at
im trailing a new hinge at the moment its made of extrusion plastic with a rubber strip fixed at the centre, has been tested at 50,000 cycles and can carry 150kg over 1m length so should its well within my specs
any way some pics
we have cut the hinge like this so we get an overlap on to the sides, we can seal this with a p seal
im not taking any chances so we drilled/countersunk out the hinge every 100mm, then applied sika stickaflex
the ally piece you can see is a spacer, the bottom sheet is fitted under the lip on the hinge, the top sheet that comes over the top overlaps the top part of the hinge, it just to guarantee our seal
we cant build this on the bench as we want a custom fit to our rear, and this can only be achieved instu, we have packed out both sides to about 5mm and hung the top timber on the hinge and well here is the pics
the ply profile is the door ends so to speak we can afford to screw through here as the heads will not be seen i have missed a few pics here in my hast, basically we fitted the bottom timber the filled in the rest, a couple of the timber had to be cut at 45 degrees as one is need on the upper corner and the one below which ties into the floorthe hinge works as it should but we keep testing to see if there is any bind
we use plenty of stickaflex here as were not using any fixings, we then rub stikaflex into the edges to seal ply
then fix the first sheet,
im using .9 ally sheet here, the blue colour is the protective coating, only costs a couple of pence, helps in a tight garage
i have only glued the top half as i have to bend the lower half manually when the glue goes off, its just a lot easier, keeps flex to a minimum,
this is the top sheet folded over 70mm and we have a 10mm overlap over top of the hinge, this bend had to be spot on as an deviation here throws it out on the opposite end of the sheet, should have took a pic i had 8 g clamps lined up for the bending
i took the rear door off today and finished the bending, i know its short, but i have an 80mm drip strip to fit and clean it up
thats the front end glued , again only up to the first bend,
back to work on monday so things will be going a bit slower now,
catch you all later
Last edited:
hi all, well i have a small bit of progress.
finished the trim on the rear door, i used a strip of ally checker plate 125mm deep, this extends just about 15mm below the ply floor, the reason is simple, any water runs off below all my woodwork, just another precaution
the closed joint sits perfect
just need to get hold of some over the centre catches fit the rear tail lights fit the interior light, and line the inside.
i want to carry some light equipment on top so im building a removable bespoke roof rack, i have a lenght of 75mm x 50mm x4mm ally channel for brackets and the spars
i put 2 10mm threads into the top for the spar joint
then went about fixing them to the walls using 8mm bolts and captive nuts on the back
these bolts are temps, im going to use allen head bolts which look a lot better
now that the captive nuts are fitted i can get on with the insulation in the roof then fit the ally skin
the wirings in for the two cabin led lights and the phone chargers,
kitchen next i think.
catch you all later
finished the trim on the rear door, i used a strip of ally checker plate 125mm deep, this extends just about 15mm below the ply floor, the reason is simple, any water runs off below all my woodwork, just another precaution
the closed joint sits perfect
just need to get hold of some over the centre catches fit the rear tail lights fit the interior light, and line the inside.
i want to carry some light equipment on top so im building a removable bespoke roof rack, i have a lenght of 75mm x 50mm x4mm ally channel for brackets and the spars
i put 2 10mm threads into the top for the spar joint
then went about fixing them to the walls using 8mm bolts and captive nuts on the back
these bolts are temps, im going to use allen head bolts which look a lot better
now that the captive nuts are fitted i can get on with the insulation in the roof then fit the ally skin
the wirings in for the two cabin led lights and the phone chargers,
kitchen next i think.
catch you all later
hello all, well im very busy at the moment and im not getting the hours in to get this camper out of the garage, maybe its not a bad thing the way the weather is at the mo.
so were am i, ah yes, i have started on the roof sheets , this was very difficult due to the high roof, again these were pre bent and glued with sikaflex then strapped with some old cargo straps just to keep the pressure on
there are no rules how you achieve this, just as long you get to the same result
the roof is covered with 2 sheets bonded in the middle, the sikaflex is a good product really pleased with it
this is my new window opening, wasnt happy about the joint half way up, its got a healthy dose of sikaflex so it should not be a problem, so paul keeps saying
pauls appearance, just cutting the excess off, and belt sander to finish
im using a caravan window, 900mm x 500mm , these are so easy to fit, i managed to find a complete piece including part of the original caravan wall, so i had a template also, again sikaflex around the rubber
just got to get hold of some internal trim to finish
wasted a hour making the brackets for these over the centre catches, they are just to big
these are rubber rear lights, still not sure about them, then again which ones do look right, im fitting an led light into them.
and to finish i have applied the first coat of paint, ( international boat paint ) in grey, i have a 2.5 litre tin so i should get 3 coats
im sure i ordered the matt, this looked a bit shiny. i have not seen it dry yet.
well that's me till next time
so were am i, ah yes, i have started on the roof sheets , this was very difficult due to the high roof, again these were pre bent and glued with sikaflex then strapped with some old cargo straps just to keep the pressure on
there are no rules how you achieve this, just as long you get to the same result
the roof is covered with 2 sheets bonded in the middle, the sikaflex is a good product really pleased with it
this is my new window opening, wasnt happy about the joint half way up, its got a healthy dose of sikaflex so it should not be a problem, so paul keeps saying
pauls appearance, just cutting the excess off, and belt sander to finish
im using a caravan window, 900mm x 500mm , these are so easy to fit, i managed to find a complete piece including part of the original caravan wall, so i had a template also, again sikaflex around the rubber
just got to get hold of some internal trim to finish
wasted a hour making the brackets for these over the centre catches, they are just to big
these are rubber rear lights, still not sure about them, then again which ones do look right, im fitting an led light into them.
and to finish i have applied the first coat of paint, ( international boat paint ) in grey, i have a 2.5 litre tin so i should get 3 coats
im sure i ordered the matt, this looked a bit shiny. i have not seen it dry yet.
well that's me till next time
Last edited:
hi all,
started on the exterior trim and the wheel arch's today, purchased some 1/2 x 1/2 x 1/16 a length of 3" x 1" x 1/8 ally angle and a sheet of 5 bar checker plate, cut to 100mm x 2.0m lengths
used the 3x1 on the arches, in one piece , mitred, folded screwed and glued
im going to fix a short mud flap to keep some of the crap off the walls
now on with the lower trim, this has been fixed 12mm below the floor as a sought of drip edge, keeps the water away from the floor.
again no fixings just sika stika flex
the small trim is a pain but worth it in the end its also a second seal for the ally sheet and the plywood wall.
im still not sure on the colour and the paint, i have been looking at alternatives alreadys
refitted the roof bar brackets with the new allen head bolts, very good, and started the trim between, again these are just glued
started to fit the window into the door, not for the faint hearted already broke one
these doors are from a motorhome side locker, the window is a must,
i only put this pic in as forgot to get one with the window installed
yes the cup fits perfectly, this is the reason for the build. lol
got a small delivery from Hong Kong today 10 no cob lights for the rear kitchen, i have put 2 of these into my trucks interior lights, will post some pics soon, a very good upgrade, clean white light.
that's me, will catch you all soon
started on the exterior trim and the wheel arch's today, purchased some 1/2 x 1/2 x 1/16 a length of 3" x 1" x 1/8 ally angle and a sheet of 5 bar checker plate, cut to 100mm x 2.0m lengths
used the 3x1 on the arches, in one piece , mitred, folded screwed and glued
im going to fix a short mud flap to keep some of the crap off the walls
now on with the lower trim, this has been fixed 12mm below the floor as a sought of drip edge, keeps the water away from the floor.
again no fixings just sika stika flex
the small trim is a pain but worth it in the end its also a second seal for the ally sheet and the plywood wall.
im still not sure on the colour and the paint, i have been looking at alternatives alreadys
refitted the roof bar brackets with the new allen head bolts, very good, and started the trim between, again these are just glued
started to fit the window into the door, not for the faint hearted already broke one
these doors are from a motorhome side locker, the window is a must,
i only put this pic in as forgot to get one with the window installed
yes the cup fits perfectly, this is the reason for the build. lol
got a small delivery from Hong Kong today 10 no cob lights for the rear kitchen, i have put 2 of these into my trucks interior lights, will post some pics soon, a very good upgrade, clean white light.
that's me, will catch you all soon
Last edited:
hi all,
well i havn't been to busy lately small progress and all that, so here go'es
looking back the last post was fitting all the lower skirt finishing the trim around the roof and the the equal angle around the sides
looking at the paint work, it has grown on me sought of shows the ally trim in a better light.
my interior lights turned up
these are just cheap led's from hong kong with switches, there bright enough
finished back door, i will have to get some pics of the led reg lights
with the door finished i set about fitting.
i have also have fitted a vent in the lower half.
just got to fit the twin locks these are both left handed and are standard with many caravan/motor home
on the market for a kampa geyser after a little chin wag with Chris, thanks, will suit me perfectly,
just picked up a small stainless sink which at this stage will be foldable or built into a pull out draw under the geyser, early days.
fitted a new 13 pin euro plug on the truck and the camper, i bought a power sensing relay for the fridge.
thats me for this evening, will finish the post in the morning, so catch you all later
well i havn't been to busy lately small progress and all that, so here go'es
looking back the last post was fitting all the lower skirt finishing the trim around the roof and the the equal angle around the sides
looking at the paint work, it has grown on me sought of shows the ally trim in a better light.
my interior lights turned up
these are just cheap led's from hong kong with switches, there bright enough
finished back door, i will have to get some pics of the led reg lights
with the door finished i set about fitting.
i have also have fitted a vent in the lower half.
just got to fit the twin locks these are both left handed and are standard with many caravan/motor home
on the market for a kampa geyser after a little chin wag with Chris, thanks, will suit me perfectly,
just picked up a small stainless sink which at this stage will be foldable or built into a pull out draw under the geyser, early days.
fitted a new 13 pin euro plug on the truck and the camper, i bought a power sensing relay for the fridge.
thats me for this evening, will finish the post in the morning, so catch you all later
hi all,
just started to build the battery/gas bottle box, im using 2 x 55ah gel batteries at the moment with a view of changing later, the box is built using marine ply, lathe frame, glued and screwed then lined with ally and 1/2 equal trim, the box is split into two sections is vented and im going to fit the fuses in here as well.
i didnt want a hinged lid as you have to space the box off the wall to open, so opted for over the centre catches simple p seal around the top to seal, built the lid with 18mm ply as i can see myself standing on top.
checker plate for the top folded on each face 20mm.
home made folder
centre catch fitted
now fix it to the frame and feed the cable and hose in to it
should be taking the camper out of the garage today, fingers crossed
thats me for now gents
just started to build the battery/gas bottle box, im using 2 x 55ah gel batteries at the moment with a view of changing later, the box is built using marine ply, lathe frame, glued and screwed then lined with ally and 1/2 equal trim, the box is split into two sections is vented and im going to fit the fuses in here as well.
i didnt want a hinged lid as you have to space the box off the wall to open, so opted for over the centre catches simple p seal around the top to seal, built the lid with 18mm ply as i can see myself standing on top.
checker plate for the top folded on each face 20mm.
home made folder
centre catch fitted
now fix it to the frame and feed the cable and hose in to it
should be taking the camper out of the garage today, fingers crossed
thats me for now gents
hi all,
fitted the battery box to the rails and threaded the cables
electrics aint my bag so paul got on with the batteries relay and fuse box
i did buy a habitation relay, but could not find a good diagram with the same colour coding and paul didnt want to blow it, so he fixed a 5 pin relay, he says it will do the same thing
with the electrics finished i had to fit the lid and get a pic, i think it looks good.
didn't get the camper out of the garage today, and still have the gas side of things to sort out.so maybe next weekend
well thats me till next time catch you later
fitted the battery box to the rails and threaded the cables
electrics aint my bag so paul got on with the batteries relay and fuse box
i did buy a habitation relay, but could not find a good diagram with the same colour coding and paul didnt want to blow it, so he fixed a 5 pin relay, he says it will do the same thing
with the electrics finished i had to fit the lid and get a pic, i think it looks good.
didn't get the camper out of the garage today, and still have the gas side of things to sort out.so maybe next weekend
well thats me till next time catch you later
hi all,
well its out at last
first impression, its grey and ugly like me,
front end is heavy, like me it, will grow on me, i hope
my kampa geyser water heater turned up Thursday, only to find it leaks, so will have to wait for a replacement spun it up and its not that bad for a small unit shut the shower head down and the pump continued on, thats when i found the leak, it still thought it was in demand, oh well.
fitted the legs to the rear door, these fold up and fastened with a toggle, they can be adjusted to suit the ground, and the door is lined and the kitchen lights are fitted,
these are cob lights from china, fitted with a remote control unit, i think they are designed for interior light replacement as they come with three different fittings, they are spot on, pun intended.
now the kitchen
well its out at last
first impression, its grey and ugly like me,
front end is heavy, like me it, will grow on me, i hope my kampa geyser water heater turned up Thursday, only to find it leaks, so will have to wait for a replacement spun it up and its not that bad for a small unit shut the shower head down and the pump continued on, thats when i found the leak, it still thought it was in demand, oh well.
fitted the legs to the rear door, these fold up and fastened with a toggle, they can be adjusted to suit the ground, and the door is lined and the kitchen lights are fitted,
these are cob lights from china, fitted with a remote control unit, i think they are designed for interior light replacement as they come with three different fittings, they are spot on, pun intended.
now the kitchen
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