DIY: Camper Shells
- 1). Measure the bed of your truck for the length and width, and the height from the bed to the roof of the cab.
- 2). Draw the plans of your camper first to determine the amount of lumber you will need for the project. The camper will be framed first with 2x4s and 2x6s and covered with plywood.
- 3). Build one side frame with a 7-foot horizontal base to rest on the cabin bed. A 10-foot horizontal cab-over beam will extend 2 inches above the roof of your cab. A third 9-foot beam will support the roof.
- 4). Measure four vertical posts from 2x4s according to the height of your cab roof. Cut them to size using a skill saw.
- 5). Connect the horizontal beams with the 2x4 posts, placing one post on each end and two in the middle. Position one post 2 feet from the back of the shell, and the other 1 foot from the front, with 4 feet of space in the middle.
- 6). Cut a 2x4 at 8 feet in length with a skill saw.
- 7). Connect the top beam to the middle beam with four 2x4s.
- 8). Repeat Steps 3 to 8 to construct the second side wall.
- 9). Screw the assembled walls together using a drill and rust-proof 3-inch deck screws. Then cover the frame with plywood, securing it with 1-5/8-inch deck screws.
- 10
Using a skill saw, cut six 2x6 boards 64 inches in length. - 11
Raise each side into a vertical position. You will need someone's help. - 12
Build the front wall first by placing two 2x6 boards between the top and bottom of both walls. Secure them with 3-inch deck screws. Cover the front wall with plywood using 1-1/58-inch deck screws. - 13
Place two 2x6 boards between the walls at the top and bottom of the rear of the shell and two more as ceiling joists, each 2 feet in from the ends of the walls. Secure them with deck screws. - 14
Measure the distance from the top of the roof to the front of the cab-over beam. Then cut two two 2x4s to size with a skill saw, each end at a 45 degree angle. Cut another 2x4 piece of plywood 64 inches in length. Frame your scoop with these boards, securing them with 3-inch deck screws. - 15
Measure the sides and front of the scoop and cut three pieces of plywood to size. Place the plywood pieces on the scoop and secure them with 1-5/8-inch deck screws. - 16
Measure and cut plywood sheets to construct the roof of the camper shell. Screw the plywood sheets to the joists and walls using deck screws. - 17
Lift the camper shell into the truck bed with someone's help. - 18
Insert two 2x4 support beams onto the back wall between the joists at a distance to accommodate a door of your choice. Between those beams, insert two more 2x4 boards horizontally. Drill the boards in place using deck screws. - 19
Insert a door of your choice into the door frame. - 20
Cover the wall around the door using plywood sheet, screwing it in place with deck screws. - 21
Secure the camper shell to the pickup bed by drilling 3/8-inch holes through the plywood of both walls and into the bed rails. Use 1/4- by 2-1/2-inch bolts, with nuts and lock washers, to secure it. - 22
Caulk all ceiling joints from the inside of your shell using a caulking gun.
