Truck Cap Build for my Toyota 4x4

[Bryan1971]

Howdy. I'm starting a truck cap build for my off-road Toyota. I rebuilt the truck a few years ago with a more powerful motor and upgraded just about everything. The vision for this camper is to be able to drive into the mountains or wilderness and camp anywhere that strikes me at the moment. It will have a single bunk with storage underneath and a slide out drawer system for cooking. The design will allow me to take out the lower half to be able to use the truck for other things besides camping. Basically, it will be three pieces; the cap, the bunk unit, and a storage unit. Here are some snap shots from the sketchup design.


Construction will be baltic birch with filon skin.

[RJ Howell]

I figure you've already looked at this, but I'll mention it in case. I built a lift-top camper for my truck, yet if I was younger (or single) I would have gone this way.

https://ripcordhq.com/collections/camper-blueprints-cut-files

Several versions of this are out there now. Me, being a maker, I'd approach the build a little different..

[Bryan1971]

I have considered something like that but I believe in the KISS principle. I really like the old school look of those campers from the 70's and 80's. Here is the inspiration for my build. It's a guy I follow on Instagram.

[Bryan1971]

I've had several days off from work and was able to dig into this project. I went down to Plywood Company of Ft Worth and picked a bunch of baltic birch plywood in various thicknesse, almost $1300 worth.


I started with the sides. I used two 18mm pieces for each side. The inner sheet will be slightly smaller for the ceiling and roof supports to rest on. The supports are 1.5" tall and there will be 1.5" foam insulation between the 1/4" ceiling and the 1/2" roof section. (pictures for clarity) The side windows are 12" x 42" as will the hatch window. The window next to the cab is 12" x 20", or something close to that, I can't quite remember. I bought a basic Maxxair ceiling fan for ventilation.


I built the front shelving unit today. That was time consuming trying to make the face piece out of one piece of plywood. What a pain. I would definitely use the standard method if I had to do it over again. I believe this unit will give the shell alot of strength. I'll try to get some better pics of it tomorrow.


And just a quick shot of my shop.

[Greg M]

Nice little shop. Is that a powermatic saw?

[Bryan1971]

Nice little shop. Is that a powermatic saw?

Thanks Greg. It is the Powermatic 100th Anniversary PM1000. The jointer on the left is the 54HH I scored almost new off Facebook marketplace. That's a PM1250 Micro Dust Filter hanging from the ceiling. Laguna band saw. Dewalt planer someone actually gave me, a friend from High School. I put a helical cut head in it and it planes like a champ. My miter station has an older Dewalt in it but it still gets the job done. The drill press is a Grizzly.

[Bryan1971]

I started the ceiling today. It sits on the inner side panel and is 6mm baltic birch. the next layer will be 3/4"x1.5" stringers with 1.5" foam in-between the stringers. Next will be 12mm baltic birch followed by the filon. Doing it this way gives a nice appearance on the inside of the camper. Hopefully, the pictures will help it all make sense if I'm not describing it very well.


The front section with the curve in it had me holding my breath, but it went in without a hitch. I used the kerf bending technique.


It turned out nice I think. I'll try to get some pics of the interior soon.

[twisted lines]

Nice Job

Nicer then my last new Leer I camped in.

[pchast]

I'll second that... Very nice job.

[Bryan1971]

I haven't had much time to post anything lately. It's a busy time at the Post Office. I finished the wiring, got the insulation in, got the roof on, and got filon on everything but the back of the camper. I'll be working on the back gate and the last bit of filon tomorrow.



I used 3M 1357 contact cement to glue the filon onto the plywood.


Here's a few pics of the lighting.


This is one area light in my pitch dark garage. I think it will do!

[orourkmw]

This is really looking good. If my brother pulls the trigger on the truck he is considering, he and I may be building something very similar in the coming year. Thanks for posting