Our old camper was destroyed when one of the jacks failed. So we stripped it of all the appliances, and goods on the interior and planned to build a tough off- road camper that would take a beating and be more roomy than a traditional slide in camper. I also wanted the camper to be removable so that the truck can be used for other things.

I have to get this camper all put together before Easter Jeep Safari. So I have only a few weeks. This truck tows a trailer with our Dodge T-Rex 6x6, or pulls our Jeep behind it. The Truck is a GMC 5500 4x4. I first built a custom winch bumper for it and put in new exhaust.

Now I took it up to my buddy's shop in Idaho: Casper Customs. Cory the owner builds ultimate 4x4's and extreme rock buggies. You may have seen some of his work in TTC.

Well, this would be the first camper for Cory and I. But I new that we could do it.

Here is the truck at Casper Customs:

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904054_large.jpg


First order of business is to lay out the frame just as I designed it:

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904003_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904005_large.jpg


Now for the assembly:

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904006_large.jpg

Here is Cory making sparks fly:

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904006_large.jpg

Nex putting things in an upright position:

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904008_large.jpg


It looks like a jungle gym :

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904012_large.jpg

A typical slide in camper weights about 2800lbs. The steel and aluminum side panels wiegh 1100lbs. So we hope to not be too much heavier that a commercial camper.

Here I am welding up the lower portion.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904021_large.jpg

Cory fabing up the jack mounts.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904015_large.jpg

Here is some of the bracing going in.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904016_large.jpg

Some of Cory's nice work

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904017_large.jpg

I'm showing off some welds for my daughter Kelsey. She is a professional welder, so I to try and keep up with her....no way...
http://carphotos.cardomain.com/ride_images/4/462/4809/38654904014_large.jpg

Does it look like a camper yet??


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904019_large.jpg


Stay tuned for more pictures from the shop. Lets see if we can get this shell done in three days.

I told Cory that we should call his shop Casper Customs Custom Campers.... Say that 4 times real fast...:shaking::laughing:

Thats awesome Stan! You will love the headroom you are going to end up with. I built a similar set up for a friend and had to have a 14" tall subframe under the camper so it would clear the cab but we incorporated tool boxes in the wheel housing and the subframe allowed for sealed pass through storage, it was a bonus in one way but with the Top Kick cab design a custom camper is the way to go for center of gravity and interior space which I think you might need! Good luck, you will love what you end up with. The F-700 4x4 camper in this forum is mine, its a labor of love and I am looking forward to showing my family what I have seen in my lifetime and sharing a ton more adventure. I hope Utah is still treating you well, and I will catch you at Moab probably next year, too crazy busy this year. Thanks for flipping us over last time!

Take care,
Mark
Red Deer Alberta TTC 2004 TTC 2009

http://i1097.photobucket.com/albums/g341/markcymbaluk/Boothcamper.jpg

Quick note, make sure you have mounting flanges in every corner to fasten your interior and exterior sheeting. I ended up having to add later, works good to with aluminum but I imagine your painting the steel to avoid rust.

thanks for the tip. Nice rig and camper.


Here is our old camper set up. It only lasted one year and then the jack blew out.



http://carphotos.cardomain.com/ride_images/4/462/4801/38654900019_large.jpg

This will be much bigger when we are done. I have only got a few weeks so Cory and I will have to work fast.

Right on. What are you going to try to have done before EJS? A weatherproof box? Some interior cabinetry? Fully finished? Ambitious in any case...

Windows, cabinetry, pluming, beds, fridge, stove, bathroom, and pool table.....OK weel maybe mot the pool table, but everything else. Cory and I are doing alot in a little time. But Cory and I are pretty darn fast.

Damn, I've been building mine for two years and it's still a ways away from being finished. But I am... slow.

Nice fab work and nice use of the Alpenflage. :D

Next installment:


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904017_large.jpg




It almost looks like a camper....lol



http://carphotos.cardomain.com/ride_images/4/462/4809/38654904019_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904022_large.jpg


More bracing for the jack mountshttp://carphotos.cardomain.com/ride_images/4/462/4809/38654904024_large.jpg


Now for the siding, roof done.


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904026_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904027_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904028_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904034_large.jpg


Pre drill each hole and then set in each screw. That is hard on your arms.... 567 down...... 478 to go....

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904036_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904037_large.jpg



http://carphotos.cardomain.com/ride_images/4/462/4809/38654904039_large.jpg

corner and roof flashing:


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904042_large.jpg



Cory was a wiz with the flashing.


Coming up next the jacks...

Nice fab work and nice use of the Alpenflage. :D

I love the Alpenflage jump suits, they are real thick and warm. Great for welding and hiding in the alps.

Nice build so far! So is that the finished camper in the garage in the background?



http://carphotos.cardomain.com/ride_images/4/462/4809/38654904054_large.jpg

Yes but not finished yet. Need the Jacks and then the lift on to the truck.

Cool build!

What size/thickness tubing are you using for the frame?

What thickness are the (aluminum?) siding panels?

Are the panels glued on with anything, or just screwed?

Thanks!

Great build, nothing like starting a project while you're under the gun for time! :laughing:

What did you decide for insulation for this thing?

There is two different types of tubing. The main frame and cross piece are 3/16 thick 1x1.5 square tubing 2.5 lbs per foot. The tubes in between, roof, inner floor are 14ga 1x1.5 at 1.5 lbs per foot.

Then aluminum sheets are .040 mil and are prepainted on both sides.

We used a metal construction adheisive first and then screwed the panels in, one screw every foot except for stress areas where we put one screw every 6 inches. Silicone was also added on overlaps and on the roof. The roof will get a plasiti -coat when done to seal it.

Insuation will be 1.5 inch polystyrene, sandwiched between aluminum sheets.

looks awesome, cant wait to see more progress

Now insalling the Jacks:


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904043_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904044_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904048_large.jpg



We have Lift - Off!!!!!


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904049_large.jpg

Now on to the truck.


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904055_large.jpg




Looking good.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904057_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904060_large.jpg




Now it is time to work on windows, flooring, and interior. good start so far.:)

Total time for build:


3 days. Way to go Casper Customs!!!!

Are the jacks pinned on in some way or are they mounted permanently? I can foresee some bent jacks and brackets if they aren't removable.

Wow! Very impressive work so far, keep the pics coming. Looks like with your motivation and the speed you work at you'll meet your goal of EJS.

Are the jacks pinned on in some way or are they mounted permanently? I can foresee some bent jacks and brackets if they aren't removable.

They bolt right on and off.

Great custom camper build. Gives me incentive to do something similar for my M818 6x6.

I didn't see it mentioned anywhere, but what are your floor dimensions?



.

You should also put a link to this build thread in the "Tow Rigs and Trailers" forum on PBB. A lot of guys there would enjoy this build but may not think to venture into the "Expedition Vehicles" forum.




.

Dimensions are:

16 ' overall length
6' over hang over the cab ( queen sixed bed)
10' floor length
7'6" width
8' tall...... could almost play basket ball inside...:shaking:

I will start on the flooring, and electircal and punch the holes for the windows starting tomorrow.


This thing is solid.


by the way how do you link to another forum page?

Subscribed

by the way how do you link to another forum page?

I'd just copy the link to this thread and start a new thread in the other section and say "If you're interested, here's the thread on my home built flatbed truck camper: www._____________"

I've thought about doing this on a 1 ton flatbed. Cool to see it come together.

that's a great camper one question on the insulation is it the white polystyrene/foam or a diff color the only reason I ask is the white is an open cell vs. Owens Corning makes a pink closed cell that has a bit better r value and doesn't have an issue with water/mold due to it's a closed cell and will not absorb the water looks like you did beyond a good job with sealing exterior at any place that water would find so water getting to the foam would be an issue but the better R value that the Foamular can give you than the normal polystyrene would be an plus in some of the places I've been

Another thing we see with the open cell (usually white)foam in an application like that is crumbling just from road vibration. It basically will fall apart inside the walls and there is a loss of insulation. I've had no issues with the pink closed cell stuff in some of the equipment we build.

Here are the next steps Flooring comes next:


Here is my wife cutting up the flooring


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904062_large.jpg



http://carphotos.cardomain.com/ride_images/4/462/4809/38654904063_large.jpg


Shawnette cutting the steel for the window frames.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904061_large.jpg

Now Skylight vents.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904064_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904065_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904066_large.jpg

Now for the windows and access hatches.


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904067_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904069_large.jpg

Access Hatch #1

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904068_large.jpg

Next Window

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904071_large.jpg



Other window complete and rear light in place.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904073_large.jpg

Great work so far, but one thing I dont like ad I am guessing you dont either is the wrinkles in the trim. What would you change to fix that if you wanted to.

But seriously, great job.

Great work so far, but one thing I dont like ad I am guessing you dont either is the wrinkles in the trim. What would you change to fix that if you wanted to.

But seriously, great job.

Thicker trim pieces would work. We started at one end and worked our way to the other to avoid just that, but each screw torques differently and that screw can dimple the trim. If it was thicker then it would not be as much of a problem. Oh well we learned. And where we go camping I am sure the trees will ding it up some more. IF we ever have to replace it I will get some thicker stuff made.

was wondering what keeps the frame's tube work from rusting ?
no primer or paint required ? or did I miss a detail ?

Very awesome...Cant wait to see the interior photos

looking good stan I will try and find some time to get down there and help

looking good stan I will try and find some time to get down there and help

You are the man that helped make this all possible.

Here is the heater and plumbing going in.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904078_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904077_large.jpg

My wife put in the insulation.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904075_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904076_large.jpg

off the point but arent you related or used to be related by marriage to a guy in New Mexico named Bill Gorman?

off the point but arent you related or used to be related by marriage to a guy in New Mexico named Bill Gorman?

I grew up in the same town( Los Alamos, NM) as Bill, and he is married to my ex-wife. He is a great guy.

How do you know him?

Bill has a son, Bill jr. he is hearing impaired and attends the new mexico school for the deaf where I was his case manager and residential supervisor for two years. At the time I had a very built YJ and he would always talk offroading and such with me and he mentioned that someone in his " family" had a lime green ram 6x6 that was in all the magazines and such and the first thing I thought of was " holy shit, thats gotta be stan"

small world isnt it!

...he is married to my ex-wife. He is a great guy.



You don't see that too often! :laughing:

its what you call a husband in law...;)

Bill has a son, Bill jr. he is hearing impaired and attends the new mexico school for the deaf where I was his case manager and residential supervisor for two years. At the time I had a very built YJ and he would always talk offroading and such with me and he mentioned that someone in his " family" had a lime green ram 6x6 that was in all the magazines and such and the first thing I thought of was " holy shit, thats gotta be stan"

small world isnt it!

It is a small world, and I know Bill Jr. He used to come to our open Paintball games. See http://www.urbansurvivors.com

Bill Jr is a cool kid. BIll Sr. is a great guy. He treats my kids great, and is a level headed, good guy to know. The kinda guy you would like for a neighbor.

On the camper build, I am working on the electrical now and there are no pictures to post of that Rats nest!:mad3:

Interior aluminum siding is in, Now Plastic panels for the roof and we start in the cabinets.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904080_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904081_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904082_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904083_large.jpg

So time for more interior. I do not work well with wood so I hired my buddy Cheston to build my cabinets, walls, bunkbeds, and table area. He does great work... a real artist.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904084_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904085_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904086_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904087_large.jpg


I finished the plumbing and built the gas lines and cheston worked around them.


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904089_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904090_large.jpg



Tons of storage

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904091_large.jpg

Subscribed

In goes the interior Trim.


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904094_large.jpg



I made an aluminium counter top

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904092_large.jpg


Next goes the fridge, had to take off the camper door and we were still 1/8 of an inch off. had to take the whole fridge apart.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904093_large.jpg




http://carphotos.cardomain.com/ride_images/4/462/4809/38654904096_large.jpg



The Throne room

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904095_large.jpg



On the outside I waterproofed the roof and then started on the gas carriers.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904097_large.jpg

Getting jealous. When I first decided to build a motorhome, imagined it would go together like this. Was just planning on thrashing to put together something quickly and hitting the road. Got sucked into a major build-up instead, and I'm not complaining, but there's something to be said for keeping it simple. Not knocking your work either. Looks like you're doing a nice job.

Shasta Cola, nice! We don't have it on the East Coast. I haven't had it since I left California, and I miss it!

^^ used to be here because I grew up in ATL and I had it when I was a kid. I did a double take when I saw it in the fridge too, its been decades since I have had it, but the headquarters of National Beverage is in Fort Lauderdale Florida, so you may be able to get it here now..

^^ used to be here because I grew up in ATL and I had it when I was a kid. I did a double take when I saw it in the fridge too, its been decades since I have had it, but the headquarters of National Beverage is in Fort Lauderdale Florida, so you may be able to get it here now..

Really, that's crazy! I've never seen it here. I assumed they were headquarted in California. I figured they were named after Mt. Shasta in California...

Awesome build!

We definitely have Shasta here in MN

Looks good... Have fun at EJS

prep for the stain


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904098_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904099_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904100_large.jpg


Stain on ready for varnish

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904101_large.jpg



Stereo box complete

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904103_large.jpg




More fuel can holders

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904102_large.jpg

:grinpimp:

Shasta Cola, nice! We don't have it on the East Coast. I haven't had it since I left California, and I miss it!

Yea we do. I drink it every night at work. :flipoff2: It's available it's just really hard to find.

looks sweet! good work. i just sold my truck camper, to get my wife her new travel trailer. im about to start building a small, light, basic tc for me.

this gives me many ideas, thx again.

Getting close

Insulation for the floor

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904109_large.jpg


Now the carpet


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904108_large.jpg


Finished Cabinets and furniture. My wife does good work.

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904111_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904110_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904107_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904117_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904115_large.jpg



http://carphotos.cardomain.com/ride_images/4/462/4809/38654904114_large.jpg




http://carphotos.cardomain.com/ride_images/4/462/4809/38654904113_large.jpg



http://carphotos.cardomain.com/ride_images/4/462/4809/38654904112_large.jpg

That's almost too pretty to do any serious off roading with. Just would hurt to see it get scratched and dinged up.

Very nice work....Makes me jealous

looks sweet good work there! :D:smokin:

It is DONE!!!!! Tool boxes on the underside, built a spare tire carrier, fuel tanks, Fuel cooler, Tranny upgrades, soloar panel on the roof, and complete interior.

Just in time for Easter Jeep Safari, WE leave tomorrow!!!!!!!

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904118_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904119_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904120_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904121_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904122_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904123_large.jpg

Now we are packed up and ready to go. Just throw the T-Rex on the trailer and head to Moab!!! See you all there!

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904124_large.jpg

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904125_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904126_large.jpg

How was all the stoarage? Plenty of room or needing more???

Tons of storage, Need some shelves in the bathroom.

Message from Moab. Camper is working great, warm, dry, and well insulated from the wind and storms we have had down here. Everything working perfect. We saw a custom camper here in moab for sale built on a Kiaser. They want $119,000 for it.

When I looked into these expedition campers the range in price for $70,000 to $150,000 with the Unimog included. Just regular Slide in P-up campers( made of wood and fiberglass) sell new for $20,000 to $24,000. There is a new trailer version here for sale at $70,000, and There is this Land rover expedition camper(much smaller than ours) for $50,000. Our cost so far $5200.

Thanks to Cory at Casper Customs for letting us use his shop and for helping to build the box. thanks to Cheston for the cabinetry work. This thing turned out awesome!! I highly recommend this to everyone who wants a camper that will last a long time.


More pictures to follow.

Lets see some pics of the complete set up trailer, truck and camper combo.. Awsome build man!!

The test of the camper in Moab was great. We were dry, warm and comfortable.
Perfect!!!

http://carphotos.cardomain.com/ride_images/4/462/4809/38654904129_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904128_large.jpg


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904130_large.jpg

On the Road again....


http://carphotos.cardomain.com/ride_images/4/462/4809/38654904131_large.jpg

A couple questions:
What do you think you have in materials?

How did you seal up the bottom?

It cost $5000.

In between each sheet of aluminun we used silicon.

How much does it weigh do you know?

What kinda mileage does this setup get ? Nice work !

Great build - and I'm just glad to see T-Rex is still alive and well. I have always loved that rig! :smokin::smokin::smokin:

what kinda mileage does this setup get ? Nice work !

x2

Awesome build! What is the powertrain in that truck and what kind of mileage does it get?

where did you get the stepf for the camper? How much? I have been looking for some similar to that. My cabover camper sits fairly high on my f-350 and the steps I have aren't cutting it. Bitchin camper. I got mine for free from my parents and was kept up its entire life so pretty hard to be at the price of free. But definitely not built like yours! Looks like a failing middle school student built it with wood that was turned away form the toothpick facotry:shaking:

way off topic, but i never realized that you were from ogden! i used to be from the bear lake idaho area. if you think you'd have the time, i know in june/july there is a big car show up there and they have a 4x4 category that i'm sure if you went you could win it :D some pansy 78 ford show truck wins it every year. they need a real truck to show them.

this is awesome.

its WAY far beyond my skills and abilities, but I have two suggestions:

1) a splash guard on the end of that counter by the sink, so you arent splashing water from dishes or washing greasy hands onto the bed in the lower bunk

2) dock lights on the side with the awning.

How did you attach the camper to the flatbed? In a couple of the pictures it looks like you have turnbuckles at the corners running from the jack brackets to the stake pockets on the flatbed, but I don't see anything to keep the camper from moving side to side.

Any updates.