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Thread: Defender 90 Roof Top Tent Build

  1. #1
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    Defender 90 Roof Top Tent Build

    Having a crack at building a hard shell roof top tent for my 90.

    Picked up a bundle of laser cut & folded alloy sheet yesterday & made a start on welding it all together.

    Tent is made from 1.6mm, 2mm & 3mm alloy sheet.

    Bed is 2030 long x 1300 wide. I will be using 12oz Australian canvas.


    Cheers
    Dave
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  2. #2
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    Had another delivery for the RTT.

    Inside the roof section im going to route in an LED strip extrusion, 20mm in from the outer edge of the ceiling insulation. This will be controlled by a touch screen much like a smart phone, it is also a dimmer + has a 30sec turn off icon. It to will be routed into the insulation in an easy to reach location beside the 4 USB charging ports.

    Also made some progress on the roof rack for the RTT, the first one we tried to weld in place, it started to buckled the roof, stop, remove & re-think design. The new one will be riveted & bolted to the roof, it will also acts as a stiffener for the roof.

    Cheers
    Dave
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  3. #3
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    Another package arrived.

    I imported a set (4) alloy hinges from Europe & sent them to my local anodizer. Very happy with the results.
    The hinges that are used by other companies are S/Steel & designed for house doors.

    I need to do all the fitting install this weekend & strip down before the RTT goes to the painter (Galway Green) next week.

    Cheers
    Dave
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  4. #4
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    Looks good. Nice to see you're having a crack yourself.
    i assume your Tig welding it all? Though about mig welding the roof rack frame on? it could limit the distortion.
    A high frequencey arc i have success at limiting distortion on ally though its a massive pain in the but especially if its thin <3mm
    Only downside of rivets would be a potential leak.

  5. #5
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    Another package arrived with some more goodies for the RTT.

    A couple of very nice locking over centre latches powder coated & a pair of 500N struts for the heavy lifting.
    I also got to install all the sail track before it goes to the paint shop.

    Cheers
    Dave
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  6. #6
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    After receiving the nice & compact over centre latches i have realised they cannot be used with my design.

    So in my stash of gear i have a pair of electromagnetic locks that are operated remotely with a key fob.
    The rear of the RTT will look nice & clean.
    The reason i have to use the electro lock is I'm trying a new hoop & bar system to keep the entry awning in place & stop it from flapping in the wind. The bar runs across the back of the RTT base when not in use, so no 2 part lock can be used.

    Cheers
    Dave
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  7. #7
    BigBlackDog Guest
    There nothing better than people getting out and making things the way that is best for them, and doing it to a high quality standard. Well done sir

    Rod

  8. #8
    VladTepes's Avatar
    VladTepes is offline Major Part of the Heart and Soul of AULRO Subscriber
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    Would you build for someone else?
    It's not broken. It's "Carbon Neutral".


    gone


    1993 Defender 110 ute "Doris"
    1994 Range Rover Vogue LSE "The Luxo-Barge"
    1994 Defender 130 HCPU "Rolly"
    1996 Discovery 1

    current

    1995 Defender 130 HCPU and Suzuki GSX1400


  9. #9
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    Quote Originally Posted by VladTepes View Post
    Would you build for someone else?
    Vlad, are you in a position to purchase??

  10. #10
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    Let's just finish & test 1 first. It is designed with commercial intent

    Cheers
    Dave

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