2022 Forest Edition - DIY Wedge Camper Build

[Jdyer8989]

Hey everyone,

I wanted to make a thread during my build, but ended up not getting to it until now. I built this camper over last winter and used it many times over the summer. This truck has become everything I imagined and has helped me explore so many places. If anyone is interested in building there own wedge camper hopefully this thread will help. I am glad to share any files I have to assist in anyone building their own.

A big reference for this build was from Ripcord's thread on the Tacomaworld forum. Worth checking out if you are going to build one yourself.

https://www.tacomaworld.com/threads/how-to-diy-wedge-camper.604686/

The project started with purchasing the truck in July 2022. I ended up getting a 2022 FX4 with the forest green Splash package. I didn't know the Splash package was even a thing when I bought it, I just liked the color.

I bought the truck new with 0 miles and from July 2023 to now I am up to 34,000 miles. No major problems so far. My thoughts on the truck are mostly good. I really love driving it, but my major complaints are it makes a very loud wining noise when driving slow and it has a vibration when accelerating. I ended up taking the truck to the dealer several times for these issues and you can guess the outcome...not much help! I pretty sure the vibration is due to the driveline angles. I did find out how to get rid of the vibration though. Just install a 300lb camper an it is gone!

First step on the truck was to get some new tires. I eventually want to put on 33" tires, but I found a full set of Bronco wheels for cheap so 32" for now.

First step of the camper was to design everything in CAD. I measure the bed of the truck several times and designed the space frame using steel square tubing. The wedge camper is built using 8020 aluminum extrusion. I made the tent dimensions 52" wide by 100" long.

To help with the height of the frame I ended up trying to position the CAD model onto a photo of the truck.

More to come...

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[Jdyer8989]

The 8020 frame went together quick using the the brackets recommended from Ripcord's build. The corner brackets I used would make a gap between them so I 3D printed filler pieces. These were sealed using RTV in the final assembly.

Next was the frame. I think there was over 80 feet of tubing to make the space frame. With minimal Tools it was not fun. The fame cutting was done with a portable bandsaw, a hacksaw and an angle grinder. Since I had the design in the computer I ended up printing paper templates to wrap around the tubes to give me the miter cuts for the more complicate tube cuts.

I built the top and bottom rectangles making sure they were square. Instead of making an elaborate jig to hold the vertical pieces in place I 3D printed corner blocks that allowed me to clamp the vertical supports to the top and bottom frames. These blocks had the exact angles of the vertical tubes and the frames. They actually made the assembly of the frame quite easy. After clamping the block in place I could even install it onto the truck to make sure it looked good.

Tacked the frame together and made sure everything looked good on the truck.

The frame looked good so I started welding it solid. Also added the bracing into the frame.

 

[xplorre]

Dude, good stuff

 

[jflogerzi]

I approve this message. good shit!

 

[Jdyer8989]

More welding and grinding and then it was ready for paint. It was a professional paint job. Spray cans in my buddy's backyard.

The Steel frame and the other components were sealed using a combination of cork gasket and lots of silicone.

The majority of the panels are made from an aluminum composite material. Its a common material for making signs. The the panel consists of a thin plastic sheet with a couple thousands of an inch thick of aluminum bonded to each side.

I used this material for the roof and the doors because its light weight, but I was nervous about it's strength for the bed floor. There shouldn't be much weight on the floor above the cab but I wanted to be sure I would never run into problems in the future. The floor is sandwiched between the steel frame and the 8020 frame so it would be a nightmare to replace if it ever cracked. I ended up using an aluminum sheet for the floor. I designed the floor in CAD and had a local laser shop cut it. I separated it into 4 pieces to keep the cost down.

Next was to assemble the 8020 frame onto the steel frame. Many others used the T nuts in the 8020 and then run a bot through the steel fame into the T nut. I heard this could be quite difficult because the T nuts can easily side in the 8020 and not line up with the holes added to the steel frame. I ended up using carriage bolts in the 8020 and sliding the threaded portion into the steel frame.

The panel behind the truck rear window was riveted on. No rear window, but I don't really mind.

 

[Jdyer8989]

I used piano hinges for the doors. To help with water proofing I overlaid some waterproof fabric over each hinge and sandwiched it between the frame and the doors. The hinges were riveted to the frame and the doors were bolted to the hinges.

The doors were a pain to cut. I used the frame to trace the shape onto the aluminum composite paneling and then slowly cut each door. I only had a circular saw and a jig saw so they are far from perfect. I originally planned to have a local sign shop cut them on their CNC router, but it was way to expensive. Aluminum angle was riveted to the panels to help stiffen them up. I added a sliding window to the back door. Only decided to add the window because it was free!

I don't have to many photos of the tent because I had some help with the sewing. I got the tent dimensions from the CAD model and laid out the fabric on my living room floor. Take my word for it, if you live in an apartment this is big project to take on. It will consume most of your rooms! I am lucky to have a coworker that is a great sewer so she helped my out. I added three windows with bug mech and a small awning on the back window. I used the same method as Ripcord's build to mount the tent to the frame. I installed Keder rails to the frame and sewed loops into the ends of the fabric.

 

[SamIAm]

can't wait to see the finished project

 

[Jdyer8989]

I wanted new suspension on the truck because of the terrible FX4 shocks. the stock shocks were very soft and the truck drove like a boat.

I decided on bilstein 6112 for the font and 5160 shocks for the rear. I also added Old Man Emu 1.7" Lift Rear Leaf Spring Kit to offset the weight of the camper. I am so happy with this setup. The truck rides great!

There is a shim under the drivers side leaf spring and the pin on the OME springs is not long enough to go through the shim into the axle. I removed the pin and added a small section of a roll pin. It was a little smaller than the pin so I welded the roll pin to the pin and ground smooth.

Needs bigger tires!

 

[harry wilson]

Great build buddy

192.168.100.1 192.168.1.1​

 

[MXGOLF]

WOW awesome work Justin.

 

[Jdyer8989]

At this point I wanted to be done with the build and get the camper on the truck so Did not take many more pictures of finishing the camper. I know these posts have been brief but hopefully everyone liked the build and I hope it might help anyone that may want to tackle a project like this themselves. If anyone needs more info let me know. I have CAD modes, cost sheets, part drawings and more. Enjoy the final photos!

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