270 replies to this topic

[ski3pin]

I'm starting a new topic to cover this part of our new adventure, getting a new camper. This augments two prior threads -

 

We are Getting a New Camper and

 

Our First Camper Finds a New Home

 

and will cover the build process of our new camper.

[ski3pin]

I stopped by All Terrain Campers on Oct 28^th and caught a glimpse of the new camper in its infancy.

 Here's the floor pack.

 

 

 

all the aluminum tubing ready to form the frame

 

 

 

and the ply board for the underside of the cabover section.

 

 

 

 

 

I was back down at ATC the end of last week. We removed our first camper to double check dimensions from all our notes. Measure twice, cut once.

 

 

 

 

When we started with a pop up camper 4 years ago, we were experienced outdoor people but had no experience at all with truck camper camping. We were learning everything from scratch, how all the systems operate, and how to tweak it all to fit our needs. With 236 nights spent in our first camper, we believe we’ve now got it dialed in. It works. We’re happy. We know what we want.

 

I want to thank Marty and Jeff at ATC for one of the best birthday gifts ever in allowing me to hang out and even help with the building of our new camper. Yup, I got to do some cutting, drill some holes, help muscle some plywood around, and work at not getting in the way. I do know my way around tools and equipment and am a follower of Red Green’s advice, “If the women don’t find you handsome, they should at least find you handy.”

 

Our new camper will be very close to the dimensions of our old camper. It fits the truck well and the roads we travel. Jeff talked us into an extra inch of width.

 

Marty and I started in on the floor pack.

 

 

 

 

 

 

 

The two sides are completed.

 

 

 

 

Jeff was busy at cutting aluminum and laying out the frame for the front of the camper.

 

 

 

 

The welding began.

 

 

 

 

The bed board for the cabover section was cut to dimensions and ready.

 

 

 

 

Marty worked on the material for the lift panels.

 

 

 

 

And they were soon cut to size. The lift panels are two inches higher to give us a bit more headroom when popped up.

 

 

 

 

The pieces were moved over to the bench for assembly.

 

 

 

 

Chad assembled the six hinges and cut them to size.

 

 

 

 

The hinges were attached to the panels and the bracing added.

 

 

 

 

 

 

 

The oak was selected for the sliders and the bed pull.

 

 

[ski3pin]

The back frame including the rear door placement was carefully laid out. Jeff gave expert advice on additional framing to properly support attaching and carrying a rotopax gas can on the back wall. Thanks Jeff!

 

 

 

 

The front frame and the three pieces of the floor pack were ready for assembly.

 

 

 

 

Jeff welded up the back frame.

 

 

 

 

 

 

 

The pieces were now ready to put together. This is starting to look like a camper!

 

 

 

 

Marty started in on getting everything lined up and put together.

 

 

 

 

It all came together.

 

 

 

 

Next, the floor pack gets painted. The Lady got to work with the roller.

 

 

 

 

She is both handsome and handy.

 

 

 

 

This is so much fun to watch the build unfold.

 

 

 

We’ll keep this updated and hope you enjoy this also.

 

To be continued…………………………………………

[MarkBC]

Very cool, ski3pin. Thanks for documenting this.

Must be exciting to see it come together -- at your own hands, too!

[Bseek]

This is amazing. How lucky to be able to be hands on, but benefit from the professionals. Watching this as it develops.

[highz]

Enjoyed following the process.  And you get to be part of the build - how cool is that? Look forward to the next steps.

[takesiteasy]

Enjoyed following the process.  And you get to be part of the build - how cool is that? Look forward to the next steps.

x2. Very fun to follow along.

[Casa Escarlata Robles Too]

Very interesting how it all comes together quickly.Great you can get to help.

Thanks for letting all of us share .

Frank

[takesiteasy]

Ski, did I read in there somewhere that you had a birthday recently? Don't remember seeing an announcement. In any event, happy birthday!

Edited by takesiteasy, 11 November 2013 - 01:41 AM.

[ski3pin]

Ski, did I read in there somewhere that you had a birthday recently? Don't remember seeing an announcement. In any event, happy birthday!

 

tomorrow, Veterans Day. Thanks for the happy birthday!