Recent content by Surftransplant

Forgot to mention I upgraded the truck too ha, 2021 double cab long bed SR5 handles the camper much more gracefully. Added ICON vehicle dynamics configurable leaf packs with the +600lb configuration and it corners much better. Will eventually do the front end too.

Well it’s been a while the camper is turning 4 this summer and doing just fine. Resealed the hinges to the frame and have regasketed the camper/bed joint a few times with no other major issues. Some upgrades I’ve made over the last couple years. 1. More windows - from motion windows in the...

I have continued with some upgrades but haven't posted any on here in a while so I figured its time for an update. Recently added some custom motion windows - 1/4" tempered glass solex bronzed mirror with sliding screens. Also built a frame for the fairing to eliminate any contact with the cab...

Made some updates adding a roof rack made with 80/20 stock components and a solar powered vent. The cross bars are .75" x 1.5" anodized aluminum. I made some G10 spacers so that the 5/8" stainless bolts would clear the lip of the roof. Stock gussets connect the brackets to the crossbars. After...

Looking good! I was lucky to be able to take 5 weeks off and spend 3+ of them on this project. Keep trucking!

The next steps were the mounting of the gas struts to the pop up roof and designing and building of the tent. This part I planned to do more on the fly because I knew I needed the final dimensions and it would be easiest to build this with the camper parked right next to the workshop. I was...

Once the hinges were mounted to the panels, the other half of those hinges was mounted to the painted steel frame with neoprene adhesive tape from McMaster Carr. The aluminum frame was then mounted ontop of those hinges (with all of the nuts already paced to align with the holes). Some of these...

Thanks for the feedback and encouragement guys. To keep things going, after about a week the Plascore panels and 80/20 extrusions showed up. Had to ship the panels freight because of their footprint. To give a quick overview there are two rectangular frames made from 3" x 1.5" 80/20 extrusion...

I apologize for the radio silence but my summer has been insanely busy. I also didn't have a computer after turning in my work one mid July until last week when I bought one before grad school. I am happy to say that the camper is complete enough to be used and I have stayed in it a few nights...

They now provide a deflection calculator on their website that is very helpful. You're right, it's only .09" with a 30" overhang and my maximum expected load. Shouldn't have any issues. https://8020.net/deflection-calculator

Thanks for the helpful input. I’ll look into that further. I was thinking with the distributed weight of the top frame, the extrusions on the bottom frame, the roof, anything mounted to the roof rack (multiple surfboards or paddle board), and 2 people in the bed might be enough to flex it...

Really appreciate the documentation on your build. Have you had much issue with flex on the overhanging section? Can you share which 80/20 extrusion profile you went with? I'm kicking off a similar build and am currently extending my steel frame foward but looking at any opportunities to cut...

Thanks for sharing that is a very helpful thread with a lot of the same challenges! Seemed like he didn't have issues with the flex of the 80/20 in the overhang over the cab... I'm leaning toward welding some 1/8" x 2" steel bar under the overhanging part of my steel frame to make a T profile...

I'm using 1" x 1.5" x .12" Rectangular Tube for the uprights on the frame but doing the rest out of .125" x 2 1/2" flat bar. The flat bar makes a lip for the sleeping platform to rest on and provides a base for the 80/20 extrusions to bolt to. You are probably right that I could go with angle...