DIY Cabover Camper

[helderman86]

OK, Team Maverick. I just got back from a 2600-mile drive from Colorado to California and back with the camper. Here are my thoughts.

Pros:
• I got caught in the middle of a weird Wyoming winter storm with 50+ wind gusts and the camper did not implode
• I liked having my bike and gear safely locked in the camper
• I like the adventure of being able to sleep wherever/whenever
• When I did sleep in the camper, I was warm and felt safe even in a sketchy Walmart parking lot
• Not much wind noise and didn't affect drive quality

Cons:
• MPG went WAY down to 25 (Hybrid). I was driving 80mph 90% of the time

Conclusion:
• Not worth the hit to MPG on long drives. I spent $120 more on gas. That's enough for a hotel room.
• I think it can be a benefit for shorter drives or camping trips where you'll be in the same place multiple nights
• It was a fun project and I'm glad I tried it but...
• I'm taking it off, and building something more aerodynamic

I want to see what you come up with next. I want something my son and I can sleep in and utilize the sliding rear window for ac in the summer months. I wonder if I could build something that still has a cab over for storage but only be a bit higher than the cab I’m 6’ and 350#. So I would need to either sleep across the width of the bed rails or on the bed floor. As for the shower comment someone mentioned. Loves gas stations are about $15 for showers. YMCA membership or planet fitness may be better options. I want to be able to do 2-3 week road trips with the son. I wish I could afford a pop up tent but not sure I would even enjoy it with all
The set up and tear down.

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[Muggy]

Team Maverick! Wanted to share my recent DIY camper build. Its 2” rigid foam insulation, wrapped in canvas and coated with Tightbond II (sometimes called Poor Man’s Fiberglass or PMF), then painted with rubberized roofing paint.

First time building with these materials. Learned a lot and a few things will do differently next time. I consider this a prototype and will likely build something different in the future, but for now, I’m satisfied. Took about 3 weeks, weighs around 150 pounds, cost around $300, gas mileage went down to 33 mpg (Hybrid) with mixed driving.

Full size bed, room for me, my bike and a few supplies. Not really meant for long camping trips, just quick overnights, and occasional solo bike trips.

2400 mile trip coming up in two weeks.

NOTE: Interior is unfinished for now. If I love it, and it works for me, I'll finish the interior with an automotive carpet.

I love this!
I also built my own side rail tie down things like you did!
I just started building one for myself but with an overhang on both sides. I know it will cut way down on the mileage, but it's not really a concern for me (for now). I'm still at a point where I can change the design a bit without wasting too much money in materials. I have thought about making it lower and extending lengthwise but ugh!! I don't know!
I'm using 1.5" Foamular. The outside is 75" wide. I havent figured out how I am going to attach it. I have the sides and the top all cut out but not glued together, (I will be putting in some corner bracing, but I'm not sure how to reinforce the cabover area. Will wood rails like yours be enough?) I need an extra body for help and warmer temps. It has been really cold here in NH. I still need to figure out the bottom shelf that will sit on the rails, and if i will need to use some plywood for extra support. I did the 4" notches to hold it together like puzzle pieces. (so I'm going to need some filler for all the goofs) What kind of glue did you use? What size wood are you using for the supports? I need to make some ribs to help support the span of the roof.

So if anyone has a suggestion, please let me know.
Thanks

 

[wax87]

OK, Team Maverick. I just got back from a 2600-mile drive from Colorado to California and back with the camper. Here are my thoughts.

Pros:
• I got caught in the middle of a weird Wyoming winter storm with 50+ wind gusts and the camper did not implode
• I liked having my bike and gear safely locked in the camper
• I like the adventure of being able to sleep wherever/whenever
• When I did sleep in the camper, I was warm and felt safe even in a sketchy Walmart parking lot
• Not much wind noise and didn't affect drive quality

Cons:
• MPG went WAY down to 25 (Hybrid). I was driving 80mph 90% of the time

Conclusion:
• Not worth the hit to MPG on long drives. I spent $120 more on gas. That's enough for a hotel room.
• I think it can be a benefit for shorter drives or camping trips where you'll be in the same place multiple nights
• It was a fun project and I'm glad I tried it but...
• I'm taking it off, and building something more aerodynamic

I was thinking something more like this, however it would need to be much bigger for a camper.

 

[gfowkes]

I love this!
I also built my own side rail tie down things like you did!
I just started building one for myself but with an overhang on both sides. I know it will cut way down on the mileage, but it's not really a concern for me (for now). I'm still at a point where I can change the design a bit without wasting too much money in materials. I have thought about making it lower and extending lengthwise but ugh!! I don't know!
I'm using 1.5" Foamular. The outside is 75" wide. I havent figured out how I am going to attach it. I have the sides and the top all cut out but not glued together, (I will be putting in some corner bracing, but I'm not sure how to reinforce the cabover area. Will wood rails like yours be enough?) I need an extra body for help and warmer temps. It has been really cold here in NH. I still need to figure out the bottom shelf that will sit on the rails, and if i will need to use some plywood for extra support. I did the 4" notches to hold it together like puzzle pieces. (so I'm going to need some filler for all the goofs) What kind of glue did you use? What size wood are you using for the supports? I need to make some ribs to help support the span of the roof.

So if anyone has a suggestion, please let me know.
Thanks

Hey there! Looks like you're off to a great start! Keep us posted with your progress. Sadly, I don't remember much about my camper build because I kind of winged it, figuring things out as I went.

If I were to do it again, I'd probably make some sort of sandwich board with a thin layer of plywood. It would add a bit of weight, but it would be way easier to mount stuff, like shelving, outdoor shower, traction boards, etc.

I'd also make it longer so it fits over the open tailgate. Maybe not as tall though.

I actually sold my 2022 Maverick because it had a bunch of recalls, but I recently bought a 2024.

I'm thinking of building a smaller 1-person camp pod for my new Mav. I'll post here once I get started.

 

[CaptScott5]

OK, Team Maverick. I just got back from a 2600-mile drive from Colorado to California and back with the camper. Here are my thoughts.

Pros:
• I got caught in the middle of a weird Wyoming winter storm with 50+ wind gusts and the camper did not implode
• I liked having my bike and gear safely locked in the camper
• I like the adventure of being able to sleep wherever/whenever
• When I did sleep in the camper, I was warm and felt safe even in a sketchy Walmart parking lot
• Not much wind noise and didn't affect drive quality

Cons:
• MPG went WAY down to 25 (Hybrid). I was driving 80mph 90% of the time

Conclusion:
• Not worth the hit to MPG on long drives. I spent $120 more on gas. That's enough for a hotel room.
• I think it can be a benefit for shorter drives or camping trips where you'll be in the same place multiple nights
• It was a fun project and I'm glad I tried it but...
• I'm taking it off, and building something more aerodynamic

What was your mileage before installing this? I have a 25' AWD Lariat with 4k and I only get 27.4mpg at 75mph. 25 mpg at 90mph sound good to me!

 

[urwatuis]

I love this!
I also built my own side rail tie down things like you did!
I just started building one for myself but with an overhang on both sides. I know it will cut way down on the mileage, but it's not really a concern for me (for now). I'm still at a point where I can change the design a bit without wasting too much money in materials. I have thought about making it lower and extending lengthwise but ugh!! I don't know!
I'm using 1.5" Foamular. The outside is 75" wide. I havent figured out how I am going to attach it. I have the sides and the top all cut out but not glued together, (I will be putting in some corner bracing, but I'm not sure how to reinforce the cabover area. Will wood rails like yours be enough?) I need an extra body for help and warmer temps. It has been really cold here in NH. I still need to figure out the bottom shelf that will sit on the rails, and if i will need to use some plywood for extra support. I did the 4" notches to hold it together like puzzle pieces. (so I'm going to need some filler for all the goofs) What kind of glue did you use? What size wood are you using for the supports? I need to make some ribs to help support the span of the roof.

So if anyone has a suggestion, please let me know.
Thanks

I'm wondering how things went with your camper shell. I am obsessed with the idea. I've been watching You Tube videos fro a few years now so I'm anxious to get going. I would love to know how your turned out.

 

[Glen Baker LLC]

To me the biggest challenge of DIY is not having it look like DIY.
Good Luck.
GB

 

[urwatuis]

To me the biggest challenge of DIY is not having it look like DIY.
Good Luck.
GB

that guy did a super nice job

 

[Glen Baker LLC]

that guy did a super nice job

I agree.

Unfortunately when I see the letters DIY and the word camper. Something like this pops up

 

[Glen Baker LLC]

Here's another nice looking DIY camper version on a Tacoma, with an interesting design element.

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