Whether it’s big or small, a pop-up or a hard-side, we love truck campers here at Truck Camper Adventure. We also love DIY truck campers. For sure, buying a factory, name-brand truck camper has its appeal, but so does building your own. Every DIY builder will tell you that there’s nothing more satisfying that building your own camper. Like many DIYers and restorers, Manuel Rhodes of Colorado built his camper during the pandemic when social distancing was the norm. While we’ve seen several hard-side truck campers and toppers made of wood, we’ve yet to see a DIY pop-up camper made of wood… until now. To learn more about his impressive DIY build, Manuel was kind enough to answer several questions.
Thanks, Manuel, for talking with us. Why did you decide to build your own camper rather than buy a used one?
Manuel Rhodes: For several years my post-retirement plans have included wanting to own a pop-up truck camper, so I could spend more time ice climbing and mountaineering. Unfortunately, pop-up campers can come with a large price tag, especially when customizations are involved. I simply could not justify the cost so I decided to design and build one myself.
How was your camper constructed? How long did it take?
Manuel Rhodes: Construction began on September 15, 2021, with the help of my daughter Lauren. The floor pack began to take shape as we glued, screwed, and stapled the frame together, finishing with a coat of black exterior paint. Even though the floor was completed I was still unsure if and when this project would ever be completed.
However, by October 10, 2021 the front, rear, and side wall framing were completed. The frame was test fitted several times during fabrication and was constructed using a combination of 1×2-inch, 1×3-inch, 1×4-inch, and 3/4-inch plywood, held together with construction glue, screws, and 1-inch wide crown staples.
What did you use for siding? Where did you obtain the material?
Manuel Rhodes: Once the framing was completed, I overlaid dimensions on the photos and took the images to Mac’s Aluminum in Bristol, Oklahoma where I selected the color and pattern for the siding. Within a few weeks, I returned to Mac’s to pick up the siding and trim along with Butyl tape, everything else needed to attach the siding to the frame. The owner of Mac’s Aluminum also gave me an aluminum 6-foot door frame, which I cut down to fit the specifications. The owner of Mac’s and his son were extremely helpful with this portion of the project build.
Next it was time cut out the large side window and install the siding.
How did you construct the roof?
Manuel Rhodes: The roof was constructed with plywood streamers and an aluminum perimeter frame and top. The streamers were created using four pieces of 3/16-inch plywood bonded together resulting in 3/4-inch thickness and 1.5-inch height and were finished with a resin epoxy coating. The streamers run east-west every 24 inches, with two running in the north-south direction. The rooftop material is one seamless piece of 0.040 aluminum. The custom-made 0.030 aluminum drip rail is from Mac’s Aluminum as well. My nephew Michael designed and 3D printed the corner caps. My son-in-law Brandon helped with the heavy lifting required during the numerous test fittings before the lift mechanism installation. The lift mechanism is made of EMT and incorporates four 60-pound gas struts. The roof is raised manually.
Where did you obtain the canvas material?
Manuel Rhodes: The soft-sided collapsible portions were repurposed from surplus military tent fabric, an incredibly durable material that helps retain heat. The roof vent and side window allow for ample natural light, so to help avoid drafts I decided to forgo creating windows in the tent material since I intend to use the camper in extremely cold weather. However, the addition of windows could be incorporated easily in future modifications or new project builds.
Nice! What do you heat the camper with?
Manuel Rhodes: We decided to get an inexpensive diesel heater found on eBay. The unit came with a fuel line and exhaust pipe upgrade. I utilize a 50-50 mix of diesel with kerosene above 8,000 feet in elevation for cleaner combustion. I believe this type of heater setup is a good option, if installed safely and correctly, however subpar installation methods could make for a dangerous and problematic heater.
What do you use to power the camper?
Manuel Rhodes: We use a single 100 amp hour lithium battery. The battery and other electronics are housed under the left dinette seat. The battery is an SOK 100 amp hour lithium battery. The battery is charged using a Victron solar charge controller, a Renogy DC-DC charger, two Renogy 100-watt solar panels, and a generic 12 volt fuse panel.
What features does the camper have?
Manuel Rhodes: Interior features include a front sleeping area with a standard twin bed, a dinette area with a stowable table and swivel bracket that converts easily to allow for additional sleeping space, under-seat and side wall cabinet storage, and comfortable cushions hand sew with the help of my wife Sherlly. The interior area design is a work in progress and is constantly being adapted to maximize space.
Your camper turned out great. How long did the project take? How much did you spend on everything?
Manuel Rhodes: The project build was completed New Year’s 2022. If you include the Brophy jacks and both solar systems, I spent $5,700 for everything.
Where have you taken your camper thus far? What are your overall thoughts on the project?
Manuel Rhodes: I spend time in the Rockies during both early spring and winter with typical climbing trips ranging from three to four weeks in duration, the longest stretch being six weeks thus far. The short-bed camper has kept me warm and dry at altitude and has saved me countless dollars in lodging compared to the time of and cost of construction, which means more money for climbing. Overall, the custom pop-up camper project was a huge success and I am already looking forward to the next build.
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