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Basic Tools Required

A project log for DIY Truck Camper

Open source truck bed camper for the masses.

dustinDustin 12/26/2021 at 00:040 Comments

I know I just added a log a few seconds ago, but I've got another topic I can cover here fairly easily. The tools required to build this camper should be easily accessible, multi purpose, inexpensive, and easy to use. This is a project for those of fairly low skill levels after all. The shell will be made of foam board, covered in canvas, wood glue, and paint. Working with these simple materials is quite easy if done properly. I suspect the most intimidating part will be cutting and securing such large panels. Most people do not work with 4x8 foot panels of any material. The foam is one of the easiest sheet materials to manage. 

Foam cutting is quite simple. Ideal tools include a tape measure, circular saw, large straight edge for the saw to ride against, chalk line to mark the lines, shop vac for cleanup, safety glasses, carpenters square, and a dust mask. The absolute simplest toolset I'd consider using is a chalk line, tape measure, carpenter square, foam knife, safety glasses, dust mask, and shop vac. I have a everything listed above already, so I'm ready to go there. 

For working with the canvas fabric, I'd go with a rotary fabric knife(disc shaped blade that rolls over the fabric for a clean cut), chalk line, large straight edge of some sort, and a very large table. I'd build a table especially for this project and just use it for other things in the future. Full sheets of MDF with 2x4 legs, held together with pocket screws and wood glue would give you one gigantic table with a smooth surface for cutting the fabric. Another option. Would to be lay it on the ground, hit it with a chalk line, and either cut with scissors or a utility knife. I'll build a table or two as I'll need them later, and I already have a rotary fabric knife in my leather working kit. The point of spending the extra time and effort on these tools is to make the work as easy and pleasant as possible. I don't like working with massive sheets of fabric, so it's worth it to make an 8 foot by 8 foot table with a super smooth top to work on and buy a special knife. The Fabrice could also be hung upright and a knife drawn down through it for an easy cut. Or scissors while it's hanging. Many options. I highly recommend running all the canvas through a commercial washer and dryer at the laundromat to get it nice and clean and remove folds and wrinkles. The fuzz that I've pulled out of the rough canvas could cause adhesion issues with the glue, and the wrinkles and folds will be ugly. 

For working with the wood glue, I recommend some sort of paint roller. Not sure what kind yet, but I suspect a foam roller would work well here and leave a fairly even smooth finish. To prep the foam panels, there exists a special roller tool used by bee keepers that has little barbs on it that would rough up the foam very nicely. The tiny holes in the foam allow the wood glue to get into the foam and act like tiny nails to bond the canvas to the foam. A good bond is very important to ensure strong and reliable panels. As the building materials in this construction method are an environmental nightmare, it's important to build it to last. If it has to be disposed of some day, it should be built to last many decades and earn it's keep. By that time, it may even be possible to safely recycle the entire camper. 

To hold the panels together and enforce them, I suspect bamboo skewers would do nicely. Shove them deep into the edge of a foam panels, leaving enough out to be pushed into the other panel where the two meet. Perhaps some wood glue on the skewer to hold it tight. The majority of the strength will come from the canvas and wood glue, but have the frame strong enough to hold it's shape during covering is important. I'll have to do testing and research to find a good way to hold everything together. 

For the covering and painting, I'd use standard exterior paint, paint rollers and trays, Titebond 3 wood glue, and heavy canvas drop cloth. Rough up the foam, sand it lightly, apply the canvas, roll with wood glue, allow to fully dry. Sand the outer surfaces smooth and wipe away the dust. Apply another layer of canvas and glue if needed, allow to fully dry, sand, clean. Paint, allow to dry, sand, clean. Repeat until you've got a nice surface finish. 

The tools and methods here are very simple, and cheap. Compared to wood or metal framing, this technique is ridiculously cheap and easy. It's time consuming and does require patience and care, but will provide better end results when insulation value, and weight are considered. Being essentially one giant piece, water resistance is excellent, and it will not rot easily. Before fiberglass boat building came about, canvas was the material of choice, and it's held up very well in the harshest conditions out there. 

The goal of this post was to simplify the tools and methods used, and eliminate any hesitation or intimidation related to the process. I'll include further detail and research in a further post, as well as cost breakdown and tools used. 

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