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Our custom true flatbed truck camper build thread

Jfet
Explorer
Explorer
Ok, I am going to collect random thoughts and progress pictures and put them here in a thread.

Goal: Construct a true flatbed camper with cabover, no slideouts but full 8 foot floor width inside. This will mount on a 2006 Isuzu NRR truck with a GVWR of 19,500 pounds and a current dry weight of 8700 pounds. The truck has a 20 foot flatbed that is 8 feet wide. The camper will take up 11 feet of the flatbed and the remaining area will be home to a future garage for our toys. We will install a hitch so we can pull our 17 foot Montgomery sailboat (trailer + boat is about 2200 pounds). The camper and garage will be removeable so the flatbed can be used for other purposes, or in case the truck needs extensive shop repairs down the road. Or if we are in Alaska and want to go pick up 3 cords of firewood or something 🙂

Here is a picture of the truck with some important dimensions:

518 REPLIES 518

kereams
Explorer
Explorer
Looks great! From the pictures it looks like it really killed your ground clearance though. Curious your experiences regarding clearance as you get time on it.
*2011 F350 SRW CC/LB/PSD - Mods: Custom overload springs with custom early engagement blocks~Firestone Airbags~Hellwig Big Wig Rear Sway~Rancho RS9000XL~Bilstein Steering Damper~19.5" Hankook DH01'a on steel wheels.
*2012 Chalet Ascent S95R Camper

Jfet
Explorer
Explorer
This Labor day weekend we labored. The goal was to install the 24" deep, 18" high, 48" long aluminum truck boxes purchased from Protech and we got er done. I have determined that crawling under trucks and drilling up through steel cross members while having hot chips fall all over you is not one of the odd jobs I want to do while driving around the country.

These boxes have added a vast amount of storage with a very low CoG. We made some prototype plywood holders for the four camper jacks to allow them to stow in one of the boxes without getting banged up. I will remake them on my cnc mill out of 3/4" UHMW plastic at some near future date. Still quite a bit of room above the jackstands in that box for other gear (they take up about 6 inches of the 18 inch height.




BoonHauler
Explorer
Explorer
Jfet wrote:
BoonHauler wrote:
I'm curious to hear how the furnace is working out for you? .......and wondering if you used the 1000 btu a foot method of sizing?

With as efficient of an envelope that you have I'd have to think that rule of thumb just wouldn't be very accurate. That's for tent trailers and alike.


Furnace! It has been 90 degrees during the day and 70 degrees at night.

Based on how well this thing is insulated, I think the near 20,000 BTU furnace will be overkill if anything. The tiny 500 watt AC certainly manages to keep the inside 25 degrees below the outside.

This fall we will know more about the furnace as sometimes it dips into the 20s during October.


I'll stay tuned......just wondering why you chose the 18k.
05 RAM 3500 CTD 4x4 Q/C Laramie DRW/NV5600/3.73, B&W Gooseneck, MaxBrake, PacBrake PRXB, Brite Box Fogster, BD steering Box Brace
2014 BoonHauler 3614

travelnutz
Explorer II
Explorer II
Jfet,

I built a rear door ramp for our 10,500 lb capacity car hauler/implement trailer back around 2001 I had that the trailer deck was 44" off the ground. I made a knuckle joint cable armsystem going from 6' high reinforced 2" X 2" X 1/4" wall square steel tubes slipped into 2-1/2" square welded on receivers roughly 1' from the rear of the trailer. The removable posts were anchored forward by removable steel cables going approx 8' forward to the trailers side rails welded on clevis. The knuckle was closer to full extension (open) when the ramp was on the ground leaving about 8" additional lowering for ground that was lower than the trailer's wheels. It would pull up (raise) the ramp to level or even up to the vertical position or any position by pulling on the knuckle joint with a cable on each side to a pulley yoke which was attached (driven) by a 12V 12,000 lb capacity electric purchased barrel winch that I already had. The whole cable system could have been a pulley/cable system also but I wanted the mechanical advantage that a knuckle joint gives.

The entire system was secured to the trailer using 1/2" and 5/8" hitch pins so if I wanted to remove any item it was simply pull the keeper clip and then pull the hitch pin. A couple seconds max!

The heaviest item I'd lifted with the ramp was a 5700 lb tractor with a front bucket that a friend bought cheap from a farmer down near Indianapolis which had a broken axle and couldn't be run. The farmer pushed it onto the ramp with his Bobcat but couldn't get it up onto the trailer bed. My ramp lifted it without any problem and then higher with a downward angle and a 2 ton comealong slid it right onto the bed so we could haul it the ~250 miles back here. Cabled it to a tree in his backyard with the ramp down and drove the trailer out from under it so he could repair the tractor. Worked really slick!

Just some food for thought as a possibility. I don't have any drawings of it as I built it by using my engineering knowledge and experience. Lots of combinations are possible also and as you have CAD, it will be easy for you.
A superb CC LB 4X4, GM HD Diesel, airbags, Rancho's, lots more
Lance Legend TC 11' 4", loaded including 3400 PP generator and my deluxe 2' X 7' rear porch
29 ft Carriage Carri-lite 5'er - a specially built gem
A like new '07 Sunline Solaris 26' TT

Jfet
Explorer
Explorer
Capt Eddie wrote:
Can I ask what is used to stop the side to side movement of the camper. It appears to be the tiedown tabs. The truck tiedown loops appear to be sticking out from the side of the bed. Could they be hit in that location? I am not criticizing the build, I love it. Just getting your idea on how you solved the problem.


Good question. The tiedown tabs do stick 2 inches below the camper and could technically stop the side to side movement by hitting against the flatbed. They are 1/4" thick welded steel L beam.

I have them pulling the camper down to the flatbed via torklift spring mounts fairly snug. The camper rests on a 1/4" thick rubber matt. We put a camera on the mount system and did not notice any movement at all of the mount system but we have only been on paved roads so far.

I don't know yet that there is a problem to solve but I have some ideas, including plates attached to the flatbed that come up around the camper a few inches on each side.

Capt_Eddie
Explorer
Explorer
Can I ask what is used to stop the side to side movement of the camper. It appears to be the tiedown tabs. The truck tiedown loops appear to be sticking out from the side of the bed. Could they be hit in that location? I am not criticizing the build, I love it. Just getting your idea on how you solved the problem.

Jfet
Explorer
Explorer
BoonHauler wrote:
I'm curious to hear how the furnace is working out for you? .......and wondering if you used the 1000 btu a foot method of sizing?

With as efficient of an envelope that you have I'd have to think that rule of thumb just wouldn't be very accurate. That's for tent trailers and alike.


Furnace! It has been 90 degrees during the day and 70 degrees at night.

Based on how well this thing is insulated, I think the near 20,000 BTU furnace will be overkill if anything. The tiny 500 watt AC certainly manages to keep the inside 25 degrees below the outside.

This fall we will know more about the furnace as sometimes it dips into the 20s during October.

BoonHauler
Explorer
Explorer
I'm curious to hear how the furnace is working out for you? .......and wondering if you used the 1000 btu a foot method of sizing?

With as efficient of an envelope that you have I'd have to think that rule of thumb just wouldn't be very accurate. That's for tent trailers and alike.
05 RAM 3500 CTD 4x4 Q/C Laramie DRW/NV5600/3.73, B&W Gooseneck, MaxBrake, PacBrake PRXB, Brite Box Fogster, BD steering Box Brace
2014 BoonHauler 3614

jimh406
Explorer III
Explorer III
Looks great!

'10 Ford F-450, 6.4, 4.30, 4x4, 14,500 GVWR, '06 Host Rainer 950 DS, Torklift Talon tiedowns, Glow Steps, and Fastguns. Bilstein 4600s, Firestone Bags, Toyo M655 Gs, Curt front hitch, Energy Suspension bump stops.

NRA Life Member, CCA Life Member

Jfet
Explorer
Explorer
We took our first overnight trip in the camper. We had a early Monday morning appointment to get a VIN assigned and decided to spend Sunday night at Belfair park (a state park on the Hood canal that is very close to the Tahuya ORV park).

The camper/truck is a lot easier to drive than I thought it would be and does not sway or rock really at all. The cabover design and rear camera make it very easy maneuver and I can almost fit it in a long single parking spot. This is pretty incredible for something of this size which can carry two 600 pound snowmobiles plus two 300 pound dual sport bikes and still be well under GVWR.

Fuel mileage wasn't great but was about as expected. You would think the sleek aerodynamic styling of the cabover would get us in the neighborhood of a Prius but alas it was quite a bit less than that. We got 9.5mpg with the camper and the two motorcycles on the flatbed. This is opposed to about 11 to 13mpg with just the empty flatbed. If I adjust these numbers using TC camper forum GAAP fuel reporting, we technically got 19mpg doing 65mph (woo hoo!)

I took a picture at night to see what the clearance lights and outdoor floods (only turned up to 25% power) looked like. All you can really see is the bright spots of the floods.

Next step is to get the aluminum storage boxes installed under the flatbed.

kereams
Explorer
Explorer
Awesome idea!
*2011 F350 SRW CC/LB/PSD - Mods: Custom overload springs with custom early engagement blocks~Firestone Airbags~Hellwig Big Wig Rear Sway~Rancho RS9000XL~Bilstein Steering Damper~19.5" Hankook DH01'a on steel wheels.
*2012 Chalet Ascent S95R Camper

Jfet
Explorer
Explorer
We still have some work to do on the interior, might be delayed a bit while we use the camper this summer. I will get some pics soon when we put the overhead cabinets in.

On the ramp ideas. We had an idea just now of making a simple attachment point on our short ramp for the four Rieco Titan 2000 pound camper jacks we currently lift the camper with (and thus carry with us). You could then roll the motorcycle on the ramp while it is level and raise it up to the height of the flatbed using the four camper jacks.

This has some advantages.

1) Easy to build

2) Don't have to buy anything or carry much extra stuff (already carry the jack stands with us)

3) Probably one of the most stable, safest ways to get a bike loaded solo.

4) Doesn't matter if the bike is disabled, as long as it can be pushed on a level surface

If we are in an area where there happens to be a small dune or slope we can back up near, we can just use the 6 foot ramp as a ramp and quickly load/unload.

I do admit it would be pretty slow to load the bikes in this manner, but it is a pretty temporary solution.

CAJW
Explorer
Explorer
Jfet wrote:
NSFW (it may make you want to leave early)

So sexy it hurts.



Very nice! My Mrs. is dying to see the interior and I'm interested in your loading ramp system for the bikes. Pictures would be nice,that is, whenever you're not out having fun with the new rig!
2013 AF 996, 2013 Chevy 3500 CC,LWB,4X4, Duramax, DRW, 3.73 rear, Torklift Stableloads & Tie-downs,Fast Guns, Ride Rite Air Bags, Superhitch w/ 32" extension.Big Wigs, Front Timbrens, TST TPMS-507,CubbyCam, Trimetric. TM & SC 2030 150W + 100W suitcase

Jfet
Explorer
Explorer
They are both 2011 WR250R but my wife's bike has been lowered a few inches with a special knuckle. It is a tall bike, just right for me at 6'7".

On the ramp issue, we are still brainstorming a interim fix until we build the garage pod (which will have a 8 foot + 4 foot ramp door). We loaded the bikes easily in our sloped driveway with a 6.5 foot ramp we already had but on a flat surface the bed of the truck is too high for that ramp. I was looking at the black widow 12 foot folding ramps but I don't want to spend $600 on a temporary solution. Might be time to break out the welder to hack something together...

Thanks for all of the nice comments.

noteven
Explorer III
Explorer III
WR250 and XT225?

Oh and still a great project. 🙂