Building Our New Camper

[ski3pin]

I'm starting a new topic to cover this part of our new adventure, getting a new camper. This augments two prior threads -

We are Getting a New Camper and

Our First Camper Finds a New Home

and will cover the build process of our new camper.

 

[ski3pin]

I stopped by All Terrain Campers on Oct 28th and caught a glimpse of the new camper in its infancy.
Here's the floor pack.

all the aluminum tubing ready to form the frame

and the ply board for the underside of the cabover section.

I was back down at ATC the end of last week. We removed our first camper to double check dimensions from all our notes. Measure twice, cut once.

When we started with a pop up camper 4 years ago, we were experienced outdoor people but had no experience at all with truck camper camping. We were learning everything from scratch, how all the systems operate, and how to tweak it all to fit our needs. With 236 nights spent in our first camper, we believe we’ve now got it dialed in. It works. We’re happy. We know what we want.

I want to thank Marty and Jeff at ATC for one of the best birthday gifts ever in allowing me to hang out and even help with the building of our new camper. Yup, I got to do some cutting, drill some holes, help muscle some plywood around, and work at not getting in the way. I do know my way around tools and equipment and am a follower of Red Green’s advice, “If the women don’t find you handsome, they should at least find you handy.”

Our new camper will be very close to the dimensions of our old camper. It fits the truck well and the roads we travel. Jeff talked us into an extra inch of width.

Marty and I started in on the floor pack.

The two sides are completed.

Jeff was busy at cutting aluminum and laying out the frame for the front of the camper.

The welding began.

The bed board for the cabover section was cut to dimensions and ready.

Marty worked on the material for the lift panels.

And they were soon cut to size. The lift panels are two inches higher to give us a bit more headroom when popped up.

The pieces were moved over to the bench for assembly.

Chad assembled the six hinges and cut them to size.

The hinges were attached to the panels and the bracing added.

The oak was selected for the sliders and the bed pull.

 

[ski3pin]

The back frame including the rear door placement was carefully laid out. Jeff gave expert advice on additional framing to properly support attaching and carrying a rotopax gas can on the back wall. Thanks Jeff!

The front frame and the three pieces of the floor pack were ready for assembly.

Jeff welded up the back frame.

The pieces were now ready to put together. This is starting to look like a camper!

Marty started in on getting everything lined up and put together.

It all came together.

Next, the floor pack gets painted. The Lady got to work with the roller.

She is both handsome and handy.

This is so much fun to watch the build unfold.

We’ll keep this updated and hope you enjoy this also.

To be continued…………………………………………

 

[MarkBC]

Very cool, ski3pin. Thanks for documenting this.
Must be exciting to see it come together -- at your own hands, too!

 

[Bseek]

This is amazing. How lucky to be able to be hands on, but benefit from the professionals. Watching this as it develops.

 

[highz]

Enjoyed following the process. And you get to be part of the build - how cool is that? Look forward to the next steps.

 

[takesiteasy]

Enjoyed following the process. And you get to be part of the build - how cool is that? Look forward to the next steps.

x2. Very fun to follow along.

 

[Casa Escarlata Robles Too]

Very interesting how it all comes together quickly.Great you can get to help.
Thanks for letting all of us share .
Frank

 

[takesiteasy]

Ski, did I read in there somewhere that you had a birthday recently? Don't remember seeing an announcement. In any event, happy birthday!

 

[ski3pin]

Ski, did I read in there somewhere that you had a birthday recently? Don't remember seeing an announcement. In any event, happy birthday!

tomorrow, Veterans Day. Thanks for the happy birthday!

 

[Lighthawk]

Happy Vets Day and BDay, Ski. SR says, "many happy returns"

Really cool that you and the Lady are intimately involved with the build. I was able to tour FWC factory and take photos, which certainly helped me understand my camper, since I was also new to the truck camper world.

Looking forward to the build out.

 

[craig333]

Interesting to see all the jigs they use for assembly. Thanks for bringing us along.

 

[ski3pin]

We spent the morning of my birthday back down at All Terrain Campers. Our camper was upright, the frames for the sides were completed and ready to be joined to the main unit.

Jeff started in on the welding.

The ply for the cabover was put into place……………………………

………………………………and screwed to the frame along with a bead of sealant. It looked like all those holes I drilled were working out.

The frame was shaped around the front and screwed in place prior to welding the ends together.

Marty invited the Lady along for a quick trip to the flooring store to pick out what she wanted. That was pretty cool!

The roof was laid out over the frame and the long ribs were cut and arched.

This is a well designed and incredibly strong frame work for the roof.

There was lots of welding to get done.

Our new camper is really starting to take shape! But along with that, the ATC guys have to deal with a really anxious costumer. She is working on her patience and getting better. It’s just that she knows how much fun and adventure is out there.

We went over layout of our propane lines and the routing of wiring in the walls.

We enjoyed seeing our new interior taking shape. We will spend a lot of quality time inside this camper quickly becoming our new home away from home.

To be continued………………………………………………………

 

[Casa Escarlata Robles Too]

Thanks Ski.Interesting to see just how much bow is in the roof ribs.That must change some when to roofing is installed!
I see a bow in my roof but nothing that dramatic.
Looks great.
Frank

 

[imix]

I love seeing how much care and attention goes into building an ATC, always wondered how the front of the cabover was bent/welded. I am sure the same care goes into building an FWC, but one can feel the good vibes that Jeff and Marty are puttin' in to your camper.

Just think, you will have photos/memories of the entire life of your camper, how many people can say that? Almost none.

 

[Dughlas Stiubhart]

It's great to see you, The Lady, Marty and Jeff hard at work. Hope to see you soon in your new All Terrain Camper

 

[ski3pin]

A big thank you to the ATC crew sharing the following photos of the roof construction.
The completed roof frame with the cross members in place.

Chad and Brad rolled the interior fabric over the frame.

And it is soon in place.

A view of the top of the roof with internal wiring and insulation in place.

Including the wires to the solar panel plug.

The aluminum sheeting is installed.

The crew at ATC have been wonderful to work with. How can you thank guys enough for providing a series of photos of the interior wiring and framing? They are just great people.

To be continued………………………………………………………

 

[Dughlas Stiubhart]

So that's what my camper's roof looks like on the inside!

 

[craig333]

I'b a bit surprised they're not using rigid insulation. All those pics are gonna be great to have down the road when one day you want to modify or repair something.

 

[ckent323]

It appears that there is no insulating material between the Aluminum ribs and the Aluminum roof sheet (I can't tell for sure). If not that creates a large thermal "short" allowing direct thermal conduction from inside to outside (heat moves from hot to cold).

Seems to me a thin layer of insulating material (a sheet or tape) between each rib and the skin would minimize the thermal short and help cut down heat loss. Filling the Aluminum channel with form would also help as well as minimize a volume where vapor can condense and the leak out.

I have noticed ice forming on screw heads in the ceiling of our FWC and that got me wondering if the aluminum frame is in thermal contact with the skin. I think it is.

If there is more information on this I am interested in reading about it.

Regards,

Craig