The Open Air Camper build - Callen on Dodge Short Bed

[theMec]

Having recently received my custom built Callen Camper, I'm finally at the modification stage! First a few pics, then I'll mention why I ended up with the Callen.
Clicking on an image should display a larger picture.

http://farm4.static.flickr.com/3313/3613153688_14e45cf1a9.jpg (http://www.flickr.com/photos/s_mestdagh/3613153688/sizes/l/)

http://farm4.static.flickr.com/3592/3612339615_391484d789.jpg (http://www.flickr.com/photos/s_mestdagh/3612339615/sizes/l/)

http://farm4.static.flickr.com/3604/3613155666_450b15731e.jpg (http://www.flickr.com/photos/s_mestdagh/3613155666/sizes/l/)

http://farm3.static.flickr.com/2446/3613156320_c56200bdc2.jpg (http://www.flickr.com/photos/s_mestdagh/3613156320/sizes/l/)

Specs:
To fit the Dodge short bed - 75" bed
Sidewall Height: 40"
Cabover: 36" overhang, 13" interior height
Double rear doors with standard windows 15"x29"
2- Windoors: Door dim:60"x30" Window: 90 degree 54"x15" Black, horiz. sliders w/ screens
Paneling
Insulation
1 Porch Light, 3 Dome Lights, 4 Clearance Lights
Roof mounted crank ventilation dome
weight: approx 550lbs


Here's our (my wife's & my) criteria for a camper. One thing for sure, my criteria will not be your criteria.
In no particular order:
- Able to feel nature as much as possible (big windows and/or windoors/ large opening in rear). That's why we go camping, right? Privacy is not an issue where we camp but I could see it might be in the Eastern US.
- 4x4able: not extreme roads but getting up Elephant Hill in Canyonlands shouldn't stop me. I routinely drag my hitch when crossing washes so I didn't want a camper extending past the back of my shortbed.
- Able to pack up and leave within 10 minutes.
- Fuel mileage has to be a consideration these days.
- Need to have adequate headroom to situp - in bed or otherwise. Need to be able to lean comfortably against the side of the camper. Fiberglass toppers are angled inward making this difficult.
- Room for 3 to comfortably sleep.
- The more storage inside the better. Need room for camping gear and an extensive selection of climbing and canyoneering gear. Gear on the roof leads to a reduction in mileage.


I strongly considered (and spent a lot of research on) the following:
- Aluminum flatbed w/ some kind of custom camper. Something like this from Alumline ( http://alumline.com/cgi-bin/csvsearch.pl?mydb=db7&mytp=tp3&method=perfect&ID=1 ) might have worked out ok and the pricing was decent. I could had Alumline customize as needed but it would have required too much long distance interaction without visual inspection.
- I talked extensively with Stan Kennedy at Four Wheel Campers. They couldn't do the windoors or double rear doors but they could build a shell model w/ a 36" wide rear door and big windows on EACH side for the Hawk model (which fits my short bed). Problem w/ a popup is that you lose storage over the cab and we don't want to sleep above the cab anyway because of no headroom. Despite this, we ALMOST went with the Hawk. Thanks for working w/ me on this, Stan!
I also talked w/ A.R.E. & All Terrain Campers and visited the local popup companies: Litecraft, Outfitter and Hallmark.
Briefly I considered a trailer but I do too much seaching for the perfect camp. Sometimes it's hard enough to back a truck out of a narrow forested road that's dead ended. I'd be hosed w/ a trailer.


Cons:
I tried to find someone to build a lighter aluminum frame custom camper but couldn't. In the end, my wife can't tell the difference driving w/ the Callen - at 80mph or on 4x4 terrain. So it's not a bad compromise.
Also it's not a slide-in so it's not a slide out. I could remove it but I probably won't due to the hassle. I can get 4'x8's sheets of plywood inside so I'm good.
Low tree limbs will catch on the rack. Luckily, the rack can be removed w/ 4 bolts per piece.

So that's why I decided on a Callen Camper. Time will tell if it's a good choice. With 4 weekend trips under my belt, it's looking pretty good.

Upcoming:
bench / sleeping / storage platform build
cargo net for cabover section (to keeps stuff from falling out)
awning
outside table
inside table
etc

[UHAULER]

I like it. Your requirements are about the same as mine. Very nice.

[adrenaline503]

Wow, thats REALLY nice. I love the lift up sides. I hate the cramped feeling of smaller campers and yours defiantely doesnt give that vibe. I have a flatbed and was considering a camper with the same requirements that you have. I look forward to seeing how it works out for you.

[kcowyo]

Very unique... You certainly did your homework. Good to hear you found something to work for your family.

I like the open-ness. Looking forward to seeing more of this one.


:beer:
.

[theMec]

Thanks guys!

Here's some pics of my benches / sleeping platform setup. This is nowhere near as cool as Sönke's hard-side popup camper (http://expeditionportal.com/forum/showthread.php?t=20822) setup but it's functional enough. I'll probably drill some holes at some point to save weight but I'm going camping this weekend and don't have time now.

1st two pics show the setup outside the camper. It takes 5 minutes to put it in. Note the free-standing bench can easily be pulled outside for a table.

Click on pics to display a larger size.

http://farm4.static.flickr.com/3394/3615969049_e47075d9ae.jpg (http://www.flickr.com/photos/s_mestdagh/3615969049/sizes/l/)

http://farm4.static.flickr.com/3412/3615969531_81549f05c2.jpg (http://www.flickr.com/photos/s_mestdagh/3615969531/sizes/l/)

And after clipping the side benches in place w/ 6 quicklinks (3 per side). The quicklinks are attached to a predrilled strap that I bent and screwed to the existing bolts (which attach the bed to the camper).

http://farm4.static.flickr.com/3557/3616789200_dc6d36a8e4.jpg (http://www.flickr.com/photos/s_mestdagh/3616789200/sizes/l/) http://farm4.static.flickr.com/3620/3617792527_e15d81f617.jpg (http://www.flickr.com/photos/s_mestdagh/3617792527/sizes/l/)

This last pic has the board in place for sleeping. When not in place, this board can be a backrest for lounging. Also I anticipate using this board for an inside table - after I figure out the best way to do it.
Covering all this are a number of 3" thick green foam slabs. Once I have everything dialed in, I'll get the foam pieces covered w/ fabric - like the professionals do. :ylsmoke:

http://farm4.static.flickr.com/3390/3616790318_1c0e73dca0.jpg (http://www.flickr.com/photos/s_mestdagh/3616790318/sizes/l/)

Also in the above pic is a 66 qt. Sterilte container for size. There is 14" space from the floor to the bottom of the benches.

[Desert Dan]

Wow that looks great. Very versatile and practicle!!

You could add some roll down screen side windows for buggy nights.

If you put a 45 degree angle plate on the leading edge or your rack maybe some of the branches wouldn't get hung up??

Maybe I should get a Power Wagon :)

[theMec]

You could add some roll down screen side windows for buggy nights.

If you put a 45 degree angle plate on the leading edge or your rack maybe some of the branches wouldn't get hung up??

Thanks Dan! Good idea about the roll down screen. I'll probably do something like that for the back doors. For the sides, I'll just close the windoors and slide open the screen window (in the windoors).

I think I'll just pull the racks unless I have boats up there.

I'll get some pics of my outside table and awning this weekend - when I'm camping!

Any ideas are welcome.

[Joaquin Suave]

I really dig the idea of a removeable bench. I'm going to do it in my Jeep too...If your cool with that.

As far open air goes, i couldnt agree with you more! The 3 weeks I spent in Baja (Dec. 2006), solo "open air" camping in Mayahual is one of the best adventures of my adventure filled life.

http://www.overlandhardware.com/images/Baja12_06b.jpg

A couple of thoughts about open-air campers....

First off, I'm of the belief that 99.999% percent of the people in the world are "good folks" and are not going to mess with your stuff, unless...

You provide for a crime of opportunity...Like leaving an ice chest full of beer unattended on a crowded Baja beach (like below Mulege), or a tool box sitting in the back of your truck. If you are willing to take SIMPLE steps like throwing a tarp over your stuff, or putting your gear in non-descript dry-bags, I in my heart of hearts believe that that your stuff is perfectly safe.

But to be the devils advocate...Bolt some cables (with nico-pressed loops on each end) to the front & side to your bed...And then combo lock your stuff to the cables (I have all my combo locks set to the same number).

another thing that i found useful, leave just a rubber mat for the floor and have a dry-bag just dedicated to the "home-stuff", like a nice throw-rug (that can be easily shaken out), curtins, oil lamps, etc....That can instantly turn your open-air camper into a "place of luxury", but can be stowed in a moments notice.

Build a lock-box vault in your cab somewhere and put everything of value in it. Who needs a wallet when your in the middle of no-where? I have the ignition key to the Jeep on a loop of 2mm Perlon that i wear as a neckless, everything else of value is accessable with a combination....Or is just sitting there. MAN, the feeling is so liberating!

Here is a thought...its a little out of the box, but work with me here...

You know in houses where they remove a window and replace it with greenhouse / solarioum expansion outward from the wall???
Ok, so now think of opening the side windows of your camper, folding out sections on both sides...that would create a transverce bed & storage area?

Don't laugh!...At least you didn't have me on retainer (like my clients when I come up wacky ideas for them!).

Keep up the good work!

[T.Low]

Great deal, Mec. You gotta lv it when a plan comes together. Luv the open air also.

What type of "boats" do you refer too?

Joaquin; seen your Jeep around Expo and dig it.

[Joaquin Suave]

This is sort of what I was thinking about for your side doors/windows, except that the swing up door would make the roof when the tents are "folded" out.

http://i96.photobucket.com/albums/l171/yuchym/LRTent4.jpg

BTW: I just swipped this photo from a jeep thread...Thanks Lowenbrau!

[Capt Sport]

That pull out drawer, canvas set-up on that Land Rover in the last post is very cool!

[RedDog]

I love it! Sensible size; sensible weight; high and dry accommodations; rapid set-up and departure. I can just imagine sitting there on a rainy night in the middle of nowhere with the windows cranked open playing cards and sipping whiskey listening to the rain and plotting the next days plans.

[Scott39]

Nice camper. I like it, because I`am one that doesnt need all the amenities, you add what you need as you go.

[theMec]

Everyone, thanks for the ideas and encouragement!


you add what you need as you go.
Scott39: and I've got a lot to go ..


sipping whiskey listening to the rain and plotting the next days plans
Reddog: That's what it's about, isn't it? A good day, fun night and plotting the next one and repeat .. I hear you on the whisky - actually I'm partial to Single Malt or Bourbon (no ice, please)

T.Low: I have a couple of old school (40years old) aluminum canoes from my days growing up (like 35-40years ago). Actually my Dad is keeping them until I pick them up. Now, w/ a rack I can get them.

Joaquin: What can I say? You have great ideas! Not that they fit in w/ my current set of ideas but they are great. In the future, I may make use of them. And yes, definitely steal the portable table idea. Thanks.

[theMec]

Although my daughter wants to and probably will sleep up in the cab over section ( once! ), it's really meant for three duffel bags, sleeping bags, pillows and camp chairs.

The gear kept sliding out when driving off pavement so I looked for a cargo net. I could have pieced together 2 cargo nets to fit but it seemed like a cleaner idea to make my own. I wasn't about to tie a cargo net together though.

Down to my local hardware store - McGuckins (http://www.mcguckin.com/), where they have everthing and great customer service (but a tacky web site). One clerk asked a 2nd. The 2nd said hog rings should do it to clamp the ropes togegther.

As usual w/ this thread, clicking on the pic will display a larger version of the picture - not that you need a larger pic of hog rings :).

http://farm4.static.flickr.com/3189/3638620400_b19062b839.jpg (http://www.flickr.com/photos/s_mestdagh/3638620400/sizes/l/)

I had to rebend the hog rings to square them out a bit. Otherwise they wouldn't fit around my retired fat climbing rope. Note the hog ring wrench above. This saved a lot of frustration. As usual w/ this kind of thing, if I know at the beginning what I learned by the end, I could have made it much nicer. Here's the end result:
http://farm4.static.flickr.com/3417/3638620926_d4b3f21196.jpg (http://www.flickr.com/photos/s_mestdagh/3638620926/sizes/l/)

For the top ring brackets, I used self tapping screws. I had never used these before but it worked out fine.

[Joaquin Suave]

You might want to look at the bed nets that are made to replace pickup tailgates. Thats what we us as a safety net for the upper bedroom in Casa.

http://www.overlandhardware.com/images/ca_images/CA%20table%20control.jpg

[theMec]

You might want to look at the bed nets that are made to replace pickup tailgates. Thats what we us as a safety net for the upper bedroom in Casa.

I did look at the bed nets. They were too narrow. I'd need to jury rig either one side or both sides to make it long enough. So I decided to jury rig the whole thing!

[theMec]

The hanging table setup consists of a couple of ropes clipped into drilled holes in the side of the camper. The drilling was done in the "flanges" which extend below the bed rails. Angled slots, for the ropes, were cut into the 3/4" plywood make for a secure setup. The four overhand knots underneath the board allowed for leveling adjustment.

Here's the hanging table in action (clicking on pics should display a larger view):

http://farm4.static.flickr.com/3579/3812899269_331fd2700a.jpg (http://www.flickr.com/photos/s_mestdagh/3812899269/sizes/l/)

Here's a couple of detail shots:

http://farm3.static.flickr.com/2623/3905394358_2830141eee.jpg (http://www.flickr.com/photos/s_mestdagh/3905394358/sizes/l/)

http://farm3.static.flickr.com/2505/3905394972_7430958429.jpg (http://www.flickr.com/photos/s_mestdagh/3905394972/sizes/l/)

[Scott39]

Cool idea. If you made it bigger and put one on both sides of the truck, you would have two more places to sleep. Just throw your sleeping bags on it.

[Gear]

Very Cool, the Hanging table is Great!

[theMec]

Very Cool, the Hanging table is Great!

Thanks Gear!

Scott39,
I have drilled both sides of the truck so I can move the table according to the wind. Having someone sleep there would cramp my style though. What if I had to piss out the side of the truck (w/ the table on the other side)? I think just putting a couple of pads and bags on top of the camper would be better.

[Scott39]

Thanks Gear!

Scott39,
I have drilled both sides of the truck so I can move the table according to the wind. Having someone sleep there would cramp my style though. What if I had to piss out the side of the truck (w/ the table on the other side)? I think just putting a couple of pads and bags on top of the camper would be better.

Heck, you could put two people in the cab, two on the sides, three inside, two on top, and your outdoor condo can sleep nine.:sombrero:

[theMec]

I forgot to mention where I store the board for the hanging table. I bought some 3/4" Z channel and bolted it under one of the benches. I didn't allow for board warpage though. The plywood was 23/32" thick. So I had to shim the channel up (actually down) an 1/8" w/ strips of wood.

This still allows for 13" of clearance under the table board.

http://farm3.static.flickr.com/2591/3907463317_dc900d3d46_b.jpg

[TACODOC]

great build!!!

[blupaddler]

Great ideas! I like the hanging table.
It is also cool to see a Callen outside of San Diego.

[klahanie]

Came across this pic in dustboy's thread...


http://farm4.static.flickr.com/3579/3812899269_331fd2700a.jpg

In a word: Priceless

:costumed-smiley-007

[matt s]

Love this set up. You are giving me great ideas, and I think may have saved me a ton of money (toning down my wild ideas, by seeing the simplicity of yours).

[theMec]

Klahanie - thanks :)


Love this set up. You are giving me great ideas, and I think may have saved me a ton of money (toning down my wild ideas, by seeing the simplicity of yours).

Glad to hear I may have helped. I've got more ideas coming!

[jeeper92]

I have a pickup bed trailer, id like to slide something like this in it and be done with it. WHat does it weigh?

[theMec]

I have a pickup bed trailer, id like to slide something like this in it and be done with it. WHat does it weigh?

Mine weighs 550#. Callen will build what you want though. They also do aluminum which I didn't know when I ordered mine. Callen is a family business - which is tough in today's economy. Don't expect quick turn around. We love ours though. Good luck!

[Funrover]

Great build, i really like how you have kept it simple and functionable!

[ETAV8R]

Very innovative way to stow the table.

[Ford Prefect]

Love the build. Thanks for sharing.

I learned a lot from your thread. The tables is a wonderful idea. I am pretty sure I know how I can work that out on my Jeeps as well, by attaching the ropes to the roof rack, and that will make such a nice bonus, even for lunches on day trips.

Thanks!

[matt s]

On your table storage with the z channel it looks like you could slide it out half way and have shelf out the back over the tail gate as well. Unintended dual purpose, perfect!

[shellb]

Any update to your build? Nice job so far.

[theMec]

Any update to your build? Nice job so far.

Thanks! Yeah, I have updates. Just need to get off my butt & post. Coming up:

webasto diesel heater
awning
water system - gravity feed
table legs added to center board - now doubles as bed board or inside/outside table
cushion covers - sort of a flower power motif

[Scott39]

Thanks! Yeah, I have updates. Just need to get off my butt & post. Coming up:

webasto diesel heater
awning
water system - gravity feed
table legs added to center board - now doubles as bed board or inside/outside table
cushion covers - sort of a flower power motif

Do you have a place to buy the Webasto diesel heater at a good price?:sombrero:

[ersatzknarf]

Try Marc at XPCamper...


Do you have a place to buy the Webasto diesel heater at a good price?:sombrero:

[theMec]

Do you have a place to buy the Webasto diesel heater at a good price?:sombrero:

Knowing what I know now, I'd talk to my local big rig service (trucks, motorhomes, contruction rigs). In my case, this was Stewart & Stevenson (http://www.ssss.com/) in Denver. They install these heaters daily for truckers. My S&S mechanic said they get webasto air top 2000 diesel heaters for about $1000. I see the basic kit, which is what I have, cost about $2000 online. You might get them a little cheaper on ebay - which is what I did. In my case, this was a bad move. I'll talk more about HOW NOT TO DO IT, when I write it up. Good luck!