Thread: Design and build a camper trailer - novice

Week 12 - progress, seems that FINALLY this thing is starting to look like a camper. Got all but 1 light wired up over the past week as well as plumbing almost all done. Had to make a crazy crazy pipe to fit the Series 3 filler to the tank... had to go from 70mm pipe round a 90deg bend then reduce to 1.5inch all in the space of a couple hundred mm. It was interesting to say the least, cross your fingers that the tank will fill ok.

Unfortunately I've run out of fasteners at the moment so progress has ground to a halt. Also found out that the Land Rover hinges just wont cut it for the kitchen door, so I've had to get some more stainless strap hinges.

So some pics.





Have to fix up some of the cable ties in here... the sticky back thingos don't work like it says on the packet.

Its looking very good DB,
Someone asked before about pics,, just wondering if you've made any progress with them.
I'm keenly interested as I'm about to start rebuilding my unit for the crew cab. Although somewhat smaller, I wanted to keep the weight down, but I suspect shelves and dividers will be easier to do in steel sheeting. In my first experiment/trial, I don't really have anything specific, but am using heavy wood ply.
I was going to do a steel frame with Alloy cladding and shelving etc, but still haven't decided yet.
What have you done about legs for your set up?

Thanks Chops. I'm starting to think that it will turn out ok, there has been a few times that I was worried that it would look like a backyard job...

Photos.. I can't seem to edit older posts so I can't update the link BUT let me try this:

Camper Trailer Slideshow by debruiser | Photobucket

That should be a slideshow of everything I've uploaded (cross your fingers)

I have made a 20mm RHS frame - some sections (load bearing) are 25mm. with the 40mm 'lifting tubes' all lightweight. I think sheet it with 0.6mm Ali. the floor I used a sheet of 2mm Ali. It does flex but I put some reinforcing under it, that stiffened it up BUT that shouldn't matter too much because it all sits on the trailer floor anyway and the trailer is PLENTY stiff. The steel frame I can lift on my own (i'm not that strong) the ali I could lift on my own if I could get a grip of it... So it's not Toooooo heavy. Although now I don't know if i can lift one end anymore.

The shelfs rest on 20mm RHS and have vertical supports behind. Shelfs, these things were worrying me quiet a bit! Strength vs weight and all that. Mum and Dad had a Hymer motorhome, so I went and had a squiz at that and they (Hymer) have used 3 ply for the whole cupboard set-up. What they have done is use 3 or 4mm ply for the shelf and verticals but they just put a little piece of timbre frame around the shelf and up and down front/back of the verticals. These are quiet strong, the motorhome had done 170000kms or there about from memory and these cupboards were all original equipment and non were broken. I know for a fact that Mum had been transporting canned food on the shelfs across corrugated roads. I figured that it it's good enough for Hymer to do back in the 80's, then it's good enough for me! SO I think I used 6mm ply (my shelfs are much larger than the motorhome) and put the timbre reinforcing where I think I needed it. The shelfs have turned out pretty strong, obviously I haven't road tested it yet though so time will tell.

Lifting legs:
Wow, some thought is going into these. 1st I was just going to use axle stands under the trailer, but too slow, and fiddly. then fixed length legs with plates under, can't lift the box out with them.... So bought 4 x 380kg jockey wheels for $10 each, BARGAIN! No clamps with them though. so the latest plan now is to get some pipe that will sleeve over the jockey wheel upper (after the handle is removed) then extend the centre shaft up to the hight of the pipe and attach a nut/drive device to turn it with either a drill or spanner. I then need to connect it to the camper, which is the tricky part - 32mm RHS slots into the 40mm RHS then a linch pin to secure. I'm currently thinking that I will try to make that fold down against the jockey wheel for transport but it will need to be simple and strong, so I havn't decided how to do that yet. It's a work in progress, and at least if I get the camper done I can just use the axle stands temporary until I get the legs done, that way we can enjoy my hard work and money....

That's gotta be my longest post ever

Yay the slideshow seems to work!

Don't forget Ranga's just sold version. Although designed for a flat top, rather than a trailer per se, its one of the best thought out and executed lift off versions I've ever seen and could easily be adapted to your needs.

Looking good debruiser. When we were discussing the water down the side issue some time ago, from memory, too lazy to go back and look, you talked about maybe making up a skirt so to speak.

I was driving through Yarrawonga the other day and saw a tray top ute with sides on it, just normal fold up/down type. He had a camper shell fitted to it. about 150 - 200mm above the top of the side was a sail track fitted to the camper with black canvas/vinyl fitted in it, that then went down over the sides and was held down by elastic/bungy cord as per a tonneau cover.

I thought of your build, it looked like a neat solution.

Mick

Originally Posted by Cracka

Looking good debruiser. When we were discussing the water down the side issue some time ago, from memory, too lazy to go back and look, you talked about maybe making up a skirt so to speak.

I was driving through Yarrawonga the other day and saw a tray top ute with sides on it, just normal fold up/down type. He had a camper shell fitted to it. about 150 - 200mm above the top of the side was a sail track fitted to the camper with black canvas/vinyl fitted in it, that then went down over the sides and was held down by elastic/bungy cord as per a tonneau cover.

I thought of your build, it looked like a neat solution.

Mick

Thanks Mick.

That was pretty much what I was thinking about too.... just simple and with flexibility.... But to tell the truth I had forgotten about it, I've just been working at getting the main box done and to a usable state. I keep running into little bits of not so much trouble but just things that need tweeking or are not exactly what I anticipated. For example, the water filler hose has to follow a path that kinks it, so I've had to order those hose spring things to keep it nice. Doors are a PITA to fit... and the hinges I planned on using (cut down defender hinges) wont work because of the door setup. This was much disappointing because I wanted to link a couple of things back to the car, ie, the door hinges, air intake, fuel filler, door props... but it seems to be that hinges wont be one of them.

The current fiddly bit is attaching rubber strips to the bottom of the camper to protect the trailer / camper from damage during transit. Also should deaden some of the noise. Will post a pic when I get it done.

The pics look good DB, thanks for sorting that
Looks good and strong, so I don't think you'll have any problems. As with all new things we do, just do some quick check as your going,, more for piece of mind I think over anything. But certainly worthwhile, if a problem starts, you can nail it before it becomes a real show stopper.
Top stuff, I hope mine turns out looking as good as yours dude