Coast Resorts Open Roads Forum: Our custom true flatbed truck camper build thread

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Topic: Our custom true flatbed truck camper build thread

Posted By: Jfet on 01/04/15 08:53pm

We finished up the aluminum roof on the garage pod and started work on the garage door. The roof on the garage pod was done exactly like on the main camper. We purchased 11 feet of 103" wide 0.040 continuous aluminum roof coil, placed down a layer of tyvek on the plywood, then sikaflex bonded the aluminum to the plywood just around the edges (about 2 inches on the top around the rim). After a few days for the Sika to fully cure, we trimmed the coil edges so 1.5" was hanging off the roof on all four sides. We then spread Sikaflex 252 on the upper side of the pod walls and hammered down the aluminum roof coil over the sides using a block of wood and hammer. Screws with hard rubber washers were placed around the edges to hold things down while the Sika cures. We plan to use 2 part Raptor truck bed liner just like on the camper pod to coat the roof and all of the screws/edges/trim.

The garage door which functions also as a ramp and porch is constructed of 2x1 steel tube with ladder rungs of 1x1 steel tube. It will have 3/4" marine plywood inlaid onto the ladder rungs to act as the ramp floor. The outside of the door will be 0.063" aluminum skin panels just like the rest of the pod. Total door thickness is still just 2.125" including the skin because the plywood is inlaid. It is one of the more complicated steps (building the door) because we have to calculate for hinges, locks, gaskets, etc.

I have also included a few pictures of the interior, although we have not done much on that the past few months because we need to get the garage pod done to the point it can leave our garage. We did install a two seat recliner sofa and made a pretty nice sliding panel door system for the closets that are formed by the portion of the cab overhang. We tried a few things for doors but ended up going with really nice maple plywood called ApplePly. It has 13 layers, is expensive, but looks damn good. The edges of the ply look so nice and uniform (with hardwood inner plys) that we stain them and leave them exposed as an architectural detail. The plywood is amazing straight and stable. We are likely to use it for some cabinet doors in the kitchen (earlier plan was to have doors custom made).

The track for the closet slider doors was a interesting idea we had. We wanted the doors to be able to slide past each other and thus needed twin tracks. I was not happy with regular sliding door tracks and so went with 1x2 8020 aluminum extrusion that has t-slots. I already knew 8020 had nylon sliders that would go in these slots, so we simply attached the sliders to the ApplePly doors and presto, rugged, dual slide closet doors. We will use solid walnut trim molding to hide the slides and edges. Still a lot of trim work left to do.

[image]

Posted By: bka0721 on 01/04/15 10:20pm

What are you using for keeping the sliding doors in place and locked from opening? Sliders "rack" unless the spring tensioner is set tight, but that inhibits sliding, but set at a medium and then bouncing over bumps n' things might skip the track. Like on a ski lift these applications have a roller on top and bottom of the top track. Is this what you have done?

Also, with work of this quality, you must be already thinking of the next project. Any hints?

b

Posted By: Jfet on 01/04/15 10:29pm

bka0721 wrote:

Hey, yes, good call there on the sliding doors...I knew I couldn't get anything past you! We do have spring tensioners in the top which go up into the groove and make the door impossible to bounce out (you have to compress them quite a bit to remove the door). I have some semi complicated mechanism in mind for locking the door position on the track but haven't built it yet, so right now they are free to slide back and forth. I adjusted the friction fairly tight for now and they don't slide during normal driving but I will be adding the lock mechanisms before we start our travels.

Next project...hmmm, let us finish this one first! :-)

I didn't say anything about a hydrofoil amphibious camper...

Posted By: bka0721 on 01/04/15 11:09pm

All of us here are just wanting to help and eager to see the finished product. You are doing an exceptional job and something I have never seen before. I love projects and brought things with me to work out here on the road. Sometimes it makes people pause a bit and say; "Is that a table saw in your trailer?" Of course they are right, it is.

I am coming to the end of a big project, awaiting the final shipment of a few things, slowed because of the holiday shutdown. But I do have a couple of projects already in the planning and napkin sketching phase. While you certainly have a product you will use for years, it is evident there is a lot of enjoyment and pride going into the building of this project.

Happy Travels.

b

Posted By: ticki2 on 01/05/15 06:43pm

After following along for almost two years I am anxiously awaiting the finish weight of just the camper . Very interesting project .

'68 Avion C-11
'02 GMC DRW D/A flatbed

Posted By: btggraphix on 01/06/15 09:32pm

Beautiful stuff Jfet. 2 YEARS? I hasn't even realized how long we've been following it. BTW, this is the first true flatbed TC I can remember anyone building and therefor the first one I can actually think "gee, when he gets bored of this rig and builds an amphibious vehicle and decides to get rid of this one........I know a flatbed it would look really good on". Guess I need to go back and look at that cab height measurement again [emoticon]

. The toy box would probably fit on my flatbed trailer too....

Thanks for the update!

2006 LanceMax 1191 - loaded and well-used
2005 C4500/Kodiak 4x4, GVWR 17,500

Posted By: BoonHauler on 01/07/15 09:40am

Jfet, were did you get that reading light? ..... and your switches and bezels?

I'd be very interested to find out.

Cee

05 RAM 3500 CTD 4x4 Q/C Laramie DRW/NV5600/3.73, B&W Gooseneck, MaxBrake, PacBrake PRXB, Brite Box Fogster, BD steering Box Brace
2014 BoonHauler 3614

Posted By: Jfet on 01/07/15 09:56am

Reading lights are made by OSRAM. They are white LED with a 18 inch gooseneck. Model Copilot L. I don't recall where we bought them but I can dig it up. We actually have four of them but the two above the sofa are not installed yet (you can see the wires coming from the wall in the picture).

The switches and bezels are from Blue Sea Systems. Marine type stuff for boats. They are modular so you can snap together end parts and middle parts to make a multi-gang switch plate. For example a middle part is called Contura with a part number 8266 and mates to a Contura end part number 8267. We bought these from Defender IIRC.

Posted By: Jfet on 01/18/15 06:22pm

This weekend we test fit the ramp door into the garage pod. Perfect fit of course [emoticon]

First time building a door of this type (hey, everything is a first time on this project) but I think we have a workable solution. It swings smoothly on the five hinges and secures on each side with standard trailer door swing arm latches. We need to Sikaflex bond the aluminum skin to the door and then install the 3/4" marine ply on the inset steel supports you can see around the edges. This method will keep the door the same thickness as the 2x1 steel tube framing (having the plywood inlaid).

Need to finish up the garage pod floor, wire up the lights, paint everything, install the floor covering (a rubber garage floor type material) then test fit it on the back of our flatbed. Probably mid March.

[image]

Posted By: BoonHauler on 01/18/15 06:50pm

Jfet:

You mentioned rubber flooring, I've been looking for a good flooring material for my garage as well but I've been unable to find any appropriate material that 8 feet wide and (in my case) 14 feet long.

I've been thinking about using outdoor carpeting. Is the material you're going to use in a sheet?.....how wide and long?

BTW, looking good....it's a lot of work isn't it.

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