DIY Truck Camper

The electrical system of my truck camper will consist of 2 parts: AC and DC power distribution.

I am still working it all out, but I know I want standard AC outlets and some custom DC outlets, as it will be more efficient to run things straight from the DC coming off the battery.

Battery set up:

I am hoping to run a bank of at least 4 Optima Blue Top deep cycle batteries for the camper portion, that is separate from the engine starting battery. This would allow me to run my electronics without the risk of killing the starting battery. This will all be wired up through a marine fuse block, using standard blade fuses. The batteries will be expensive, but crucial for running things such as my PC, small TV, phone chargers, water pumps, and various fans.

AC Power Distribution:

For the AC, I will be running a few large car batteries, and most likely a large inverter. This will keep all my electronics away from the engine starting battery to spare me being stuck in one place after a movie night. I plan to wire the outlets to the same code as home wiring, to ensure things are safe and reliable, even if it adds more work, weight, and cost. Better than burning to the ground after something shorts.

DC Power Distribution:

I would like a standardized DC power system in the truck, as it is more efficient than turning DC to AC, just to have the appliances convert AC back to DC again. I am considering USB Type C with the Power Distribution protocol for this. I would like to just create custom power supplies for all the permanent appliances, such as computer monitors and microcontrollers, that would allow them all to run from the USB voltage directly. This is just a fun thought to play with, but could be a very efficient and simple way to power everything from the sink water pump, to the vent fans, and phone chargers.

After bundling up and facing the northern winter winds, I finally got the measurements from my truck needed to get the plans drawn up. I decided on a simple camper that will slide in and out of the bed, and will keep the tailgate down to add an extra 2 feet to the overall length.

I have drawn up the basic walls so far, minus horizontal supports, and figured out a few other things.

I am planning on building a custom couch to wrap around the back wall of the camper so I can sit comfortably with guests.

I am using my Cricket Wireless smart phone, with 12GB of 4G and mobile hotspot to supply internet to the Raspberry Pi 3, running Openelec that will supply entertainment. I will probably keep my lenovo workstation on board as well, assuming I can supply enough power to run this stuff. I am currently using the hotspot on my phone to post this on my workstation PC. It works very very well, and I am quite pleased with it.

I have left plenty of clearance in most of the dimensions for my camper as I can always add foam insulation or rubber mats to fill gaps in and such. Better too small than too big.

The biggest challenges I face right now are financial, and time constraints. I am moving an hour away from my job and my grumpy old tuck does not like the drive every day. It is costing me almost as much in gas each month as my previous rent. Though I am in a much better situation now. I will be trying to work on this every day from now until it is completed.

Windows. I have designed a few pretty neat windows for this camper. Ordering custom cut and framed windows would be extremely expensive, so I have decided to make them myself. I am experienced enough in galss cutting to turn a bottle into a cup, and make stained glass windows. I spent a day studying and practicing with a master stained glass maker a few years ago, and learned just enough to get by. You can buy a Kobalt brand glass cutter at lowes for about $4 or so. I highly recommend dabbling in glass as it can be a very valuable skill.

I am too tired to keep rambling on, so I will leave it at this.

I want something comfortable that I can park at work without people thinking I'm a crazy red neck. I need something light weight to ease the stress on my 33 year old truck. Insulation is going to be a problem. The layout of all the cabinetry is going to be mind boggling. There are so many problems to face, but conquering them will give me the skills and a home I can truly be proud of.

The Shell:

The frame has to be very strong, but light weight and rigid. I am considering framing the walls like a house, then screwing corrugated metal sheeting to the frame. This should be pretty light and look half way decent. I would have to insulate the walls, then run an internal all of some sort. I am thinking about using a thin plywood. The part that will ha g over top of the cab will be my bed room. I think I will cut big arches out of plywood, then make a frame out of them, then simply bend the metal sheeting around the curve to make it look nice. I can cut and install all the window glass myself.

Electronics:

I will be running a 3000 watt or higher inverter with wiring run to code for a home. I will have a few outlets for things such as a projector and some chargers. My truck would be upgraded to a high performance alternator to handle the extra draw. I already installed an Optima battery for starting the engine. I plan on installing at least 1 Optima deep cycle battery to run my camper. All camper electronics will run off the deep cycle battery to ensure the starting battery can never be depleted.

Heating:

I will explore the idea of adding a second heater core to the camper, which would route engine coolant to it, then blow that hot air into the camper to warm it up as a drive. I will likely also install a 20 pound propane tank and small furnace if needed. The entire camper will also be insulated, with insulated cover panels for all windows. I also have a sleeping bag rated for -25 degrees Fahrenheit.

Cooling:

My truck doesn't have AC and probably never will. I am going to very carefully lay out all windows and vents to ensure the best airflow at any given time. Just like my truck, the camper will have vents that draw in air while moving, so I can keep fresh air in the camper. I will be using blower fans to keep air moving as well. I can always sleep with a wet tank top on if needed.