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DIY Slide in Pop-Up Truck Camper

DIY slide in pop up truck camper four wheel camper aluminum weld

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#1 toomuchDIY

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Posted 06 May 2021 - 08:53 PM

long time creeper on here finally getting around to posting.

 

i decided to do something similar to, albiet quiet different than, the ambition strikes build on YT.

 

exoskeleton built with 3" x 3" 3/16" aluminum. panels built with .040 aluminum glued to 1" blueboard glued to 1/4" birch.

 

its been quite the process so far and ive learned a lot. like not all rivets are waterproof. been talking about that one a lot lately. a lot a lot. didnt know that was one of the causes for the titanic sinking as well. thankfully this isnt the titanic.

 

this is made to fit an a 2500 silverado with an 8' bed for reference.

 

vulcan omnipro 220 welder with spoolgun

 

buying a three axis jig has been a huge help and has gotten everything within a 1/16" of an inch.

IMG_9040.jpg

 

and a chinese air fan for welding has helped with my lungs

IMG_9042.jpg

 

as you can see i plan on using this for skiing and hunting mostly with some biking and surf trips in the mix.

IMG_9044.jpg


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#2 Vic Harder

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Posted 06 May 2021 - 08:59 PM

whoa, is that a monoski I see in your collection?  I've skied on one of those for a decade or two.... 


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#3 toomuchDIY

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Posted 06 May 2021 - 09:13 PM

second step was going up and bumping out for the wheel wells.

 

here is the jig in action.

IMG_9043.jpg

 

well shoot if i didnt miss this little bump out in the truck bed that captures the tailgate.

 

63960147666__17D7915E-505E-47F6-AD41-713CC4346AD0.jpg

 

in hindsight i should have made a cardboard template and actually tested. lesson learned, the hard way.

 

 

and the fix.

63960619651__A0B40827-FE47-45D9-9057-5FF179594821.jpg

 

 


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#4 toomuchDIY

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Posted 06 May 2021 - 09:15 PM

Vic - ya ive taken it out a few times. way harder than i thought. also some ski blades just to the left.

 

gotta have the whole quiver ya know.


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#5 steve whiteside

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Posted 07 May 2021 - 01:02 AM

Very cool and adventurous of you to embark on this.  Was it very difficult to get those Aluminum welds?  Did you get many burn through spots?

 

Steve


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2012 F350 4x4

2020 Grandby


#6 toomuchDIY

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Posted 07 May 2021 - 04:11 PM

steve - as you can see here yes. the edges of the angle have a rounded edge and where they met it became tricky to not burn through. inevitably i would go through and just build it back up.

 

63970982465__1D6A6603-D19B-42FE-9EA0-AEBCA5021986.jpg

 

 

going up

IMG_9052.jpg

 

 

and up

IMG_9057.jpg

 

 

 


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#7 toomuchDIY

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Posted 10 May 2021 - 10:35 PM

building out the cabover 

 

IMG_9062.jpg

 

 

figuring out the spool gun finally

 

IMG_9064.jpg

 

 

and on the truck. it fits. thank god

 

IMG_9065.jpg


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