Project 1x1

[toyrunner95]

I am starting this thread on a camper build that I have been contemplating for a some time now. I talked to my friend the engineer today and he gave me several ideas on how to keep the load light and cheap.

Here is the idea. A basic camper that is lightweight and cheap to build. I.E. under 1000 pounds (unloaded) X under $1000 (Hense 1x1)

This is not your fancy Earthroamer, just a box. It will have a bed that converts into a couch and a table that is small. Foldable counters and a foldable sink.

Here is my first delema.

The materieals. I want something that is light weight but easily workable (no special tools so aluminium is out.) Mild steel and plywood is what im thinking. with angled edges.

What else is there.

[adrenaline503]

For under a grand, that is about it. FRP (fiberglass reinforced plastic) would make a decent weather barrier for the plywood.

[Inc]

I am building what sounds like a similar trailer. For the floor I am using an ABS plastic sheet. It is 1/4" thick and will support my weight without any center supports. You can weld the ABS plastic as well, and maybe add some side support or something to make it more rigid if you want to use it for walls. They sell welding guns at Harbor Freight for around $30. The sheet I got was free. I know a guy that forms the rear seat in police cars, made of ABS plastic. If the sheet isn't in perfect condition, they can't use them and since I know the guy, he gave me a sheet. Maybe you can check around and see if there is a local maker of those seats and snag a free sheet or a few. Good luck.

[toyrunner95]

Does anyone have experience with the FRP?

[adrenaline503]

Another thought I had was possibly build a lighweight frame out of 1x2 (you could weld a frame) and attach rigid foam to build the walls. Then attach the FRP for a barrier. You could bond the foam and the seams and edges, creating an airtight seal. I think the tough part would be sealing the edges. If you used ABS instead of FRP you could weld the seams then use a router to round them off. I have no idea what that much ABS would weigh or what it would cost.

Another nutty thought was to use wood strips and tie them together like build builders do, then fiberglass over everything. I have seen some kayaks built this way and the strength to weight ratio is impressive. Maybe fiberglass over the FRP?

And a last idea, what about using a tonneau cover for the roof? As long as you didnt plan to put much weight up there it would be fine. Its one piece and would match your truck bed dimensions so it should be easy to fit. I am considering using one to make a pop top roof on a home built camper since some of them come with a hinge assembly.

[toyrunner95]

I actually have a tonneau cover but I dont want a huge square for a roof. It will have a slight bow to it for runoff also to keep the profile slightly smaller im going to angle the roof in on the sides and back on the front. Once I get the plans made up for the shell I will post them up.

So far these are great options and very viable solutions.

I have considered the fiberglass cloth for the outside then covering that with resin. I might go to a RV builder and see what they use and how they seal it.

[adrenaline503]

I have been researching boat construction as well. There seems to be more info available and far as I can tell its all about the same. Waterproof and durable are my concerns.

I had thought about a nice slopeing or curved roof but the additional bracing and construction werent worth it. Maybe you'll be the one to figure it out.

What will the rough dimensions be? Just curious how much volume you want to enclose for 1000 lbs.

[toyrunner95]

Well I want an enclosure over my truck bed which is 8'. I don't want a cabover so perhaps 6' tall, and then 4.5-5' wide. However wide the be is. It will be a slide in so it will have a bottom. the wheel wells are the trick. i havent decided if im going to work around them or do the channel thing. I would like as much floor space possible so a channel may be necessary from the front to the back of the wheel wells and then open it up after that.

I may have to match the contours exactly and lift it out instead of sliding it. I need to mock up the floor space.

[UHAULER]

I would look at a uhaul box. They are very well built and and are bolted together so you change the size fairly easy. The side panels are 1/2" plywood with fiberglass laminating on both sides and the corners are round extruded aluminum. another nice thing about them is you can put windows wherever you want and not worry about framework, crossmembers,etc.

I was going to build my own shell and skin it with aluminum until I priced the aluminum and it was over $900 alone, add in the frame material,corner trim,hardware, etc and it gets very expensive.

I would price everything out first, I don't think you could build one for $1,000.

Check out the BULLIT XV thread to see what he is doing.

[toyrunner95]

The Uhaul is a good idea. Im avoiding aluminium because it is expensive as well as I cant weld it. Fiberglass and plywood is the way to go I think.