Pop Up Surf Camper for PNW

The next steps were the mounting of the gas struts to the pop up roof and designing and building of the tent. This part I planned to do more on the fly because I knew I needed the final dimensions and it would be easiest to build this with the camper parked right next to the workshop. I was lucky to have access to the Doyle Sailmakers Loft in Alameda, I had worked there for 3 years a while ago now and Bill was very cool with me working on something there while I wouldn't be in the way. The gas struts were 125 lb, 38", with 15" stroke from Guden. I was really impressed with the hardware and ease of install. I used 5/16" 18 t nuts tomount the strut mounting plates to the extruded frame. My process was to prop the top of the camper up (with adjustable crutches) until I got it to the desired height, then mount the gas struts, tension the mounts, and see where the top came back after we dropped it and pushed it back up.

The tent is made from vinyl coated polyester with water-resistant zippers. The bottom panels of the windows have fiberglass battens sewn into them. This makes them much easier to roll up but can sometimes get in the way while trying to pack down the tent to close the camper.




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I did all of this by measuring dimensions of the camper. At one point I questioned how perfect the tent would be and added .25" to the width and height of the center panel just in case the tent ended up too small to ensure it would be installable with that tolerance. After remeasuring after the build, it looks like the tent is exactly .25" too wide and tall on that panel which makes it harder to tension up. Overall it still looks good, but I think it would be easy to improve. I ran out of time to add additional vents beyond the window. I got the tent designed and built in 2 days over the weekend and ended up spending 33 hours on that. That probably took longer because I hadn't built any sails in 6 years, and was a bit rusty. Still really enjoyed the process. The bug screens are no-see-um mesh from seattle fabrics, which is where I bought all of these materials.

The back window does not have a bug screen. Bug screens were really time consuming to make, because adhesives didn't stick to them well and they were difficult to tension. I ran out of time and wanted to keep at least one window an unobstructed view window.

After finishing the roof and driving the camper down to CA without a fairing, I realized I probably really needed a fairing and did some quick research into low cost solutions while I was down there. I decided to use a 1/4" UV stabilized polycarbonate panel cut to size at tap plastics, some stock 45 degree brackets from McMaster Car, some rubber 1/16" gasket material, and stainless steel bolts and nylocks.

I'm really happy that up to around 55-60 mph the truck still gets over 20 mpg with the camper. The faster I go above that it starts to drop but doesn't go much under 18 mpg with the fairing which is a BIG improvement.

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Made some updates adding a roof rack made with 80/20 stock components and a solar powered vent. The cross bars are .75" x 1.5" anodized aluminum. I made some G10 spacers so that the 5/8" stainless bolts would clear the lip of the roof. Stock gussets connect the brackets to the crossbars.

After some research I decided to go with the Nicro Stainless Day/Night Plus Solar vent with built in battery. It was an easy install with a holesaw, some screws, and silicone. Happy with the upgrade so far hoping it cuts down on condensation in cold weather. https://www.fisheriessupply.com/nicro-day-night-plus-solar-battery-vent

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I have continued with some upgrades but haven't posted any on here in a while so I figured its time for an update. Recently added some custom motion windows - 1/4" tempered glass solex bronzed mirror with sliding screens. Also built a frame for the fairing to eliminate any contact with the cab. This resolved a squeak I would hear on hot days and will protect the paint going forward.

Happy to provide more detail if any one has questions - I know you're all mostly here for the pics!
 

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Well it’s been a while the camper is turning 4 this summer and doing just fine. Resealed the hinges to the frame and have regasketed the camper/bed joint a few times with no other major issues. Some upgrades I’ve made over the last couple years.

1. More windows - from motion windows in the Portland area, love them but had to upgrade the gas springs to deal with the weight.
2. Electronics box with 100AH LiFe renogy battery, 100W panel, custom soft LED interior light, max air mini roof vent, and fold out card table.
3. Bed rug made the camper much more homey, dog loves it and it reduces the risk of damaging things like surfboards. Great value at $300
4. Eberspacher S2 heater plumbed to an auxiliary diesel tank hung inside the bed fairing on slides.

Love this thing, keep putting in a couple upgrades each year. Tent probably only has 1-2 more years in it (PNW is very damp) noodling on replacing it with hard panel walls or a zip out insulated tent. We shall see. Hope y’all are getting out there!
 

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Forgot to mention I upgraded the truck too ha, 2021 double cab long bed SR5 handles the camper much more gracefully. Added ICON vehicle dynamics configurable leaf packs with the +600lb configuration and it corners much better. Will eventually do the front end too.
 

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97heavyweight

Active member
You in the Seattle area by chance? I think i've seen your rig around. I have the DCSB Tacoma with white rims and white camper.

Also you should check out Sherpa Equipment Roof Racks if you are in the market for one.

I'd love to check this thing out in person good work!
 
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