Building Our New Camper

[marty]

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

The roof frame is completely covered in a good closed cell tape. It looks like the metal in some pictures. If you look down to the picture with the roof skin you will see the tape on the edge. The insulation that is doubled up in the roof has a combined R value of almost 7. That is more than double of solid insulation.
Marty

 

[Casa Escarlata Robles Too]

IMO the "bat" type insulation is easier,more cost effected,and fills the areas better.
With ridged type each piece has to be cut to fit it's specific location and if not cut exactly to fit could leave space between framing and insulation.
Frank

 

[marty]

IMO the "bat" type insulation is easier,more cost effected,and fills the areas better.
With ridged type each piece has to be cut to fit it's specific location and if not cut exactly to fit could leave space between framing and insulation.
Frank

Hi Frank,
No the bat type that we use cost much more than the solid to purchase. It is two hours faster to install. It has a better R value than the solid.
Marty

 

[ski3pin]

Good discussion on the roof. I, like probably most others here, have read and heard lots of opinions on roofs and insulation. The Lady & my decisions about camper choice and construction are based from an experienced pop up camper user's perspective. I also know how to build things. We backcountry ski out of our camper and we enjoy bitterly cold desert winter mornings. We want a warm camper. That drove two decisions on our new camper - a small non slider window against the truck cab and the insulation in the roof and walls that ATC uses in their standard build.

 

[ski3pin]

This camper build is so cool on so many levels from seeing it transform from a stack of tubing and lumber to become a camper to daydreaming about all the wonderful adventures ahead this camper will play a prominent role in. It is hard to contain our excitement.

I was back down at the factory to check on progress and make some decisions. It is hard to stay away and again I thank the guys for their patience with me and my curiosity.

All the 12V wiring has been routed in the walls.

The roof is ready for lift panels and then joined to the main camper section.

The Lady’s choice of vinyl was laid out with the pattern for the floor.

It was a perfect fit.

To be continued………………………………………………………

 

[craig333]

i had a small leak, easily fixed but the insulation (as far as i could tell) seemed to soak up the moisture, more than a a solid piece would. Do the FWC campers have the same bow in the ceiling or is that an ATC thing?

 

[jha6av8r]

Do the FWC campers have the same bow in the ceiling or is that an ATC thing?

Yes they do. From what I can tell from the pictures, the structure looks identical.

 

[ski3pin]

What a difference a day makes.

The inside paneling has all been installed and the window/exterior openings have been cut out.

The insulation is in the walls and the aluminum siding is going on.

Also in place for a test fit is the rotopax mount on the rear wall.

Brad and Chad continue with installing the siding.

The Yakima Tracks are in place on the roof along with the plug for the solar panel.

Marty and my attention went to the placement of the bottom board I will use to build our cabinet. It would help to get it laid out now for placement of the furnace and the propane box.

Brad helped out by double checking the dimensions and that it is square to the extension below from the floor pack. This will be my cabinet for two bottom drawers.

After we fit the furnace in its place, it is then pulled out and test fired and ran for awhile to burn off any oils.

My future work space has been established and the ATC guys got right on finishing up the siding and trim.

Pretty exciting, isn’t it! The Lady said this morning that all she’s been dreaming about is camper parts and cold mornings “out there” where we wake, alone, and wait for the sunrise.



To be continued………………………………………………………

 

[craig333]

Must be killing you guys staying at home waiting. Anticipation!

 

[Casa Escarlata Robles Too]

Hi Frank,
No the bat type that we use cost much more than the solid to purchase. It is two hours faster to install. It has a better R value than the solid.
Marty

Thanks Marty.I like the "bat" type better than ridged,glad you use that.
Interesting that it would cost more.Oh well it's worth it.
Figured it would be faster to install and fill the space better.
Thanks to you and Ski for showing the construction of the campers.Very nice.
Frank

 

[takesiteasy]

Looking good, Ski3pins! I'm having fun following along. I hope the ATC boys finish up pretty soon so you can send some more trip reports our way. It's already feeling like a long, cold winter here until our next trip.

 

[Ted]

Just got back from a week on the road. Very interesting to get caught up on this build. Can't wait to see the finished project.

 

[Riverrunner]

Looking good. Cool to see how it all goes together.

 

[ski3pin]

We put in time this weekend in preparation to building the interior.

First we cut the new countertop and table and covered both in Formica. We made the table just a bit larger than the table we put in our first camper.

Most all the parts we ordered have arrived, including the new SMEV stove.

With the countertop and table ready, we moved on to cut and plane oak for book matched drawer fronts.

We also planed poplar to thickness for the drawer sides.

There’s an interesting and hard to explain satisfaction that comes from hands on labor. We’ll be putting a lot more of that into our new camper.




To be continued………………………………………………………

 

[clikrf8]

Ski3pin,
My very best wishes for more brilliant sunsets, cozy nights and gorgeous sunrise mornings in your new camper by ATC. Holding-your-breath excitement for you and your followers on wtw. Thanks for all the photos showing how your dream camper is coming to life. Happy trails to you and your Lady.

 

[ski3pin]

Ski3pin,
My very best wishes for more brilliant sunsets, cozy nights and gorgeous sunrise mornings in your new camper by ATC. Holding-your-breath excitement for you and your followers on wtw. Thanks for all the photos showing how your dream camper is coming to life. Happy trails to you and your Lady.

Thanks to everyone for your very kind well wishes on this project. We appreciate it and hope you enjoy following along as we continue.

 

[ski3pin]

It was unmistakable, the Lady’s happiness. I met her in the garage as she drove in. Instantly out of the car, prancing in place, her hands close in front with a series of quick claps, and that grin from ear to ear. “Thursday! Really? We can get our camper on Thursday!” She was thrilled.


We’ll back up a bit and share the continuing process of building our camper. A big thanks, again, to the crew at All Terrain Campers for the following photographs.

I had said that after my last visit they had gotten right on finishing the siding and trim. Here’s the documentation. The siding is on with the holes cut out for the windows.

Brad gets the camper in a comfortable position for work and completes the trim.

The windows are installed.

It is looking great.

The roof is put in place and the lift panels are installed to the main camper shell.

The inside Velcro strips for the top of the Cold Weather Pack are laid out for installation.

The side liner is laid out in preparation to be lowered around the roof.

It is then ready to be stretched over the edge of the roof.

 

[ski3pin]

The fit is perfect and the placement is just right.

The roof sheeting is carefully molded over and stapled into place. I love that nice arch to the roof.

Brad takes special care around the front corners and pop rivets are installed.

Brad then molds the trim piece around the perimeter of the roof.

It is looking good and that nice graceful arch is still evident.

I stopped by around noon the next day. I could hardly control my excitement with the sight before me.

This is really looking great!

Marty asked, “How do you like the two inch higher lift panels?”
“It is luxurious to have headroom. I can grow my hair longer now. I’m going back inside to look at it again!”

It was one of those moments where I just wanted to continue looking at our new camper. A door installed and a couple of small items and it will be ready for delivery.

“When do you want to get it?” Marty asked.
“The Lady wants to come down also when we do.”
We went in the office. I suggested Marty leave a message on her cell phone asking when she’d like to pick up her camper. I gave Marty the number.
“You’ll just get her message. She never answers her phone. Most of the time it’s not on.” I explained. Marty waited for the message. Instead, the Lady answered. Marty was a bit tongue tied, “Can’t I have the voicemail?” He recovered quickly. “This is Marty at All Terrain Campers. When can you come down to get your new camper?”

Thursday!




To be continued………………………………………………………

 

[billharr]

This has been fun watching your camper go together. Can't wait to see you putting the interior together.

I will be a week of two behind you. Have some family things to do and then I get started on the inside of my Hawk.


Bill

 

[Dughlas Stiubhart]

Looking better and better, 3pin!