Well I went and bought a set of plans from Glen L, the Alcapulco 8 foot truck camper plans.
Problem I'm having is with the Popular Mechanic plans call for a steel angle iron frame. I had my father, who works in a steel fab shop, do a rough estimate of the steel needed and weight of it. The steel ended up being about 430 lbs, that's before adding any wood to the framework to screw into. Aluminum was much lighter, but the cost was far more than what I was willing to part with, rough cost was close to $1800 for the frame with the materials and welded to shape. The steel was about $700, including the welding to shape, but unfinished, so I would still have to grit blast, grind and paint the steel. These quotes were priced for my father, if I went in it as an outside customer I would be paying far more than that, probably close to $3000 for the aluminum frame and $1800 for the steel frame.
So metal framing is out, now I'm waiting for the plans, probably do a merge of the Glen L plans with the Popular Mechanics plans to create a non cabover 8 foot truck camper.
So here's another question, I've seen some new style windows from Seitz in Germany, they hinge at the top and fold outward, and have a cassette system containing a shade and screen on the inside. Anyone have any experience with them? I've seen the Heir windows, which are common in most campers, but the idea of having a streamlined window frame with the screen and shade up or down without it blowing around or having a set of strings hanging down is kind of neat.
Also anyone recommend a door dealer? I've looked at RVSurplus, they can get one custom built, but nothing readily in stock when I called about windows and doors. (Of course it sounded like I was calling a telephone support center with a room full of telemarketers in the background)