cancel
Showing results for 
Search instead for 
Did you mean: 

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 ๐Ÿ™‚

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

518 REPLIES 518

ticki2
Explorer
Explorer
After following along for almost two years I am anxiously awaiting the finish weight of just the camper . Very interesting project .
'68 Avion C-11
'02 GMC DRW D/A flatbed

bka0721
Explorer II
Explorer II
All of us here are just wanting to help and eager to see the finished product. You are doing an exceptional job and something I have never seen before. I love projects and brought things with me to work out here on the road. Sometimes it makes people pause a bit and say; "Is that a table saw in your trailer?" Of course they are right, it is.

I am coming to the end of a big project, awaiting the final shipment of a few things, slowed because of the holiday shutdown. But I do have a couple of projects already in the planning and napkin sketching phase. While you certainly have a product you will use for years, it is evident there is a lot of enjoyment and pride going into the building of this project.

Happy Travels.

b
08 F550-4X4-CC-6.4L Dsl-206"WB GVWR17,950#
09 Lance 1191
1,560wSolar~10-6vGC2-1,160AmpH~Tri-Star-Two(2)60/MPPT~Xantrex 2000W
300wSolar~2-6vAGM-300AmpH~Tri-Star45/MPPT~Xantrex 1500W
16 BMW R1200GSW Adventure
16 KTM 500 EXC
06 Honda CRF450X
09 Haulmark Trlr

Jfet
Explorer
Explorer
bka0721 wrote:
What are you using for keeping the sliding doors in place and locked from opening? Sliders "rack" unless the spring tensioner is set tight, but that inhibits sliding, but set at a medium and then bouncing over bumps n' things might skip the track. Like on a ski lift these applications have a roller on top and bottom of the top track. Is this what you have done?

Also, with work of this quality, you must be already thinking of the next project. Any hints?

b


Hey, yes, good call there on the sliding doors...I knew I couldn't get anything past you! We do have spring tensioners in the top which go up into the groove and make the door impossible to bounce out (you have to compress them quite a bit to remove the door). I have some semi complicated mechanism in mind for locking the door position on the track but haven't built it yet, so right now they are free to slide back and forth. I adjusted the friction fairly tight for now and they don't slide during normal driving but I will be adding the lock mechanisms before we start our travels.

Next project...hmmm, let us finish this one first! ๐Ÿ™‚

I didn't say anything about a hydrofoil amphibious camper...

bka0721
Explorer II
Explorer II
What are you using for keeping the sliding doors in place and locked from opening? Sliders "rack" unless the spring tensioner is set tight, but that inhibits sliding, but set at a medium and then bouncing over bumps n' things might skip the track. Like on a ski lift these applications have a roller on top and bottom of the top track. Is this what you have done?

Also, with work of this quality, you must be already thinking of the next project. Any hints?

b
08 F550-4X4-CC-6.4L Dsl-206"WB GVWR17,950#
09 Lance 1191
1,560wSolar~10-6vGC2-1,160AmpH~Tri-Star-Two(2)60/MPPT~Xantrex 2000W
300wSolar~2-6vAGM-300AmpH~Tri-Star45/MPPT~Xantrex 1500W
16 BMW R1200GSW Adventure
16 KTM 500 EXC
06 Honda CRF450X
09 Haulmark Trlr

Jfet
Explorer
Explorer
We finished up the aluminum roof on the garage pod and started work on the garage door. The roof on the garage pod was done exactly like on the main camper. We purchased 11 feet of 103" wide 0.040 continuous aluminum roof coil, placed down a layer of tyvek on the plywood, then sikaflex bonded the aluminum to the plywood just around the edges (about 2 inches on the top around the rim). After a few days for the Sika to fully cure, we trimmed the coil edges so 1.5" was hanging off the roof on all four sides. We then spread Sikaflex 252 on the upper side of the pod walls and hammered down the aluminum roof coil over the sides using a block of wood and hammer. Screws with hard rubber washers were placed around the edges to hold things down while the Sika cures. We plan to use 2 part Raptor truck bed liner just like on the camper pod to coat the roof and all of the screws/edges/trim.

The garage door which functions also as a ramp and porch is constructed of 2x1 steel tube with ladder rungs of 1x1 steel tube. It will have 3/4" marine plywood inlaid onto the ladder rungs to act as the ramp floor. The outside of the door will be 0.063" aluminum skin panels just like the rest of the pod. Total door thickness is still just 2.125" including the skin because the plywood is inlaid. It is one of the more complicated steps (building the door) because we have to calculate for hinges, locks, gaskets, etc.

I have also included a few pictures of the interior, although we have not done much on that the past few months because we need to get the garage pod done to the point it can leave our garage. We did install a two seat recliner sofa and made a pretty nice sliding panel door system for the closets that are formed by the portion of the cab overhang. We tried a few things for doors but ended up going with really nice maple plywood called ApplePly. It has 13 layers, is expensive, but looks damn good. The edges of the ply look so nice and uniform (with hardwood inner plys) that we stain them and leave them exposed as an architectural detail. The plywood is amazing straight and stable. We are likely to use it for some cabinet doors in the kitchen (earlier plan was to have doors custom made).

The track for the closet slider doors was a interesting idea we had. We wanted the doors to be able to slide past each other and thus needed twin tracks. I was not happy with regular sliding door tracks and so went with 1x2 8020 aluminum extrusion that has t-slots. I already knew 8020 had nylon sliders that would go in these slots, so we simply attached the sliders to the ApplePly doors and presto, rugged, dual slide closet doors. We will use solid walnut trim molding to hide the slides and edges. Still a lot of trim work left to do.









Jfet
Explorer
Explorer
I did not mean we are using a 500 watt heater on battery power. The camper is parked in our driveway and I am running a 500 watt heater from our house electricity. My point was the 1700 BTU output of the electric heater on low easily keeps the camper 30 degrees above freezing. This makes me believe an order of magnitude increase in BTU from the furnace (18,000 BTU) would be plenty.

Definitely will try the camper and garage pod on the Isuzu NRR and see how things sit. The time and effort that have gone into the camper and garage make the truck itself a small part of the build if we did have to switch. It would take less than a day to do a complete switch including the under truck boxes and backup camera system if we were to find a 20 foot flatbed GMC T-7500 (they do exist but always seem to be on the other side of the country).

bka0721
Explorer II
Explorer II
I concur with btggraphix on the wait and see, before adding more. I often use the analogy of a Cafeteria line and picking things to put on your tray. Once you have gone to the end, the cashier then gives you the total. Weighing at the Scale is often the same BIG surprise. Starting out as I did, adding special items take on a whole new world of weight. As an example, my truck/service body weighed in for itโ€™s TARE ticket for registering, came in over 11,000 lbs, heavier than most peopleโ€™s Truck and Truck Camper combined. Might I suggest you scale your project as soon as you have the opportunity, before you are finished to see what your estimations and true weights really are? It keeps you from being surprised when arriving at the Cashier.

Also, running a heating element device works well when doing it on paper, but reality is this element will impact your SOC (State of Charge) of the battery/s. Thusly, the ultimate health and longevity of your battery bank. Even though a micro wave and other power heavy devices are for brief times, a Space Heater, does not. There are so many variables in maintaining batteries and solar harvesting I would not suggest this as an alternative for heating when off the grid. My battery banks are, 1,460 AmpH (combined) and 1,860 watts of solar (combined) and I would never subject my batteries for more than a few minutes of this steep draw of amps. Theory and reality always have a huge collision, when they meet.

b
08 F550-4X4-CC-6.4L Dsl-206"WB GVWR17,950#
09 Lance 1191
1,560wSolar~10-6vGC2-1,160AmpH~Tri-Star-Two(2)60/MPPT~Xantrex 2000W
300wSolar~2-6vAGM-300AmpH~Tri-Star45/MPPT~Xantrex 1500W
16 BMW R1200GSW Adventure
16 KTM 500 EXC
06 Honda CRF450X
09 Haulmark Trlr

btggraphix
Explorer
Explorer
I'd almost certainly say give this chassis a try first and see how it does (similar to what I'll tell someone with a stock dually getting a big TC.) Having said that I always really liked the idea of the GMC T series cabovers as a platform with the admitted drawback of no 4WD, but if you don't mind that it seems like would be your ticket. 3K pounds is gonna get used up quickly :). I knew that around the time of the bailout they stopped production of the TopKick and Kodiak but was never sure if they also killed the T series? I think the last model year of the Kodiak/TopKick was 08 or 09 so they had already gone to post emissions......we looked at buying a new 08(?) with the emissions. it was economics and possibly poor management choices that killed the line. Anyway, maybe they stopped bringing in the large Isuzus at the same time and for related reasons
2006 LanceMax 1191 - loaded and well-used
2005 C4500/Kodiak 4x4, GVWR 17,500

Jfet
Explorer
Explorer
Thanks everyone for the nice comments...actually starting to see the finish line in the distance (finally). Boon, we haven't really had time to use the camper in the cold weather (I don't even have a propane tank hooked up right now) so furnace results are on hold. I will say that running a electric heater on low setting (drawing about 500 watts) keeps the camper about 60 degrees when the outside temp is hovering around freezing. 500 watts/hr is about 1700 BTU/hr and the furnace is rated at 18,000.

bigcitypopo wrote:
By chance have you thought of adding a battery rack to that pod. It seems you could had 6-8 6volts there toward the front of the pod thus placing the weight almost over the axle.. It might give Ya a good boon docking edge... Prewire it for solar. And your set... Then should you ever need to off-load... The unit is self sufficent with solar and a batt bank should you need to run an inverter or such.


Yes we thought initially about adding a 2nd bank of batteries in the garage pod (the living pod already has a small battery bank) but I am starting to have overall weight concerns even on the rear axle. I think when the garage is loaded on the truck behind the camper and we have our two motorcycles in it, the overall weight will be around 16,500 pounds. The GVWR of the truck is 19,500 so that only leaves 3000 pounds for gear. Considering we have more storage than a small house on this thing, 3000 pounds is not much.

I am looking at the Isuzu FTR,FVR,FRR series (or GMC T7500) which is the slightly heavier duty version of this cabover (26,000 GVWR). It seems they stopped importing them into the USA in about 2008 (probably because of the new diesel emission requirements) so they are harder to find. They would give us about 7,000 to 8,000 pounds for gear.

Or we may just try to keep the gear down to a minimum and get by with the NRR we have.

bigcitypopo
Explorer
Explorer
By chance have you thought of adding a battery rack to that pod. It seems you could had 6-8 6volts there toward the front of the pod thus placing the weight almost over the axle.. It might give Ya a good boon docking edge... Prewire it for solar. And your set... Then should you ever need to off-load... The unit is self sufficent with solar and a batt bank should you need to run an inverter or such.
2014 RAM 2500 BigHorn CrewCab 4x2 ShortBox, 6.7L CTD
2014 Keystone Springdale 294bhssrwe - Hensley Arrow!
The best wife, 2 kids and a bunch of fun

btggraphix
Explorer
Explorer
I still can't believe how cool your project is, and how cool I expect the result to be. I'd be happy to be a fly on the wall in the corner of your shop just to have watched the whole thing take place. Thanks for sharing this thread all this time. It is truly one of the coolest build threads I've read anywhere, and certainly here on RV.net. I hope the result is every thing you hope it to be, and more.
2006 LanceMax 1191 - loaded and well-used
2005 C4500/Kodiak 4x4, GVWR 17,500

BoonHauler
Explorer
Explorer
BoonHauler wrote:
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.


Jfet ..... Just a friendly reminder we're still waiting for your furnace review ๐Ÿ™‚

I'll be ordering mine pretty soon......
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

bill_harr
Explorer
Explorer
Just another note to let you know your thread is being followed. Great work.

cewillis
Explorer
Explorer
Yes -- that is seriously professional work.
Cal

bka0721
Explorer II
Explorer II
Love this thread, oh, yeah, that neat camper and garage pod in it too!

More pics. More detail. Soon, right?

b
08 F550-4X4-CC-6.4L Dsl-206"WB GVWR17,950#
09 Lance 1191
1,560wSolar~10-6vGC2-1,160AmpH~Tri-Star-Two(2)60/MPPT~Xantrex 2000W
300wSolar~2-6vAGM-300AmpH~Tri-Star45/MPPT~Xantrex 1500W
16 BMW R1200GSW Adventure
16 KTM 500 EXC
06 Honda CRF450X
09 Haulmark Trlr