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Step 2Assembly
- 1 of the fiberglass tops has to be lowered on all sides by about 4" (This is so that the 2 roof tops will close into each other neatly) (I used a skill saw to cut off the sides)
- attach the 2 front hinges to the existing holes that are already there
- attach the 2 back folding uprights to the original holes at the top, on the bottom you will have to attach them at 90degrees and drill new holes (now you have your basic shell structure)
- close the shell and flip it upside down
- attach the reinforcing bars running lengthwise (this is to add rigidity to the bottom shell)
- align the roof rack to how you want it to sit (I spaced it evenly to distribute the weight)
- drill holes through the reinforcing bars and the bottom shell for the 4 u-bolts (it is critical that the u-bolts go through the fiberglass bottom shell, the reinforcing bars and joint the roof rack, this gives a lot of strength to the whole works)
- flip the works right side up, make a paper outline of the back hole while the 2 shells are closed, transfer it to the 1/4" plywood
- cut the back plywood and attach it to the top shell with 3 bolts
- open up the camper, attach the canvas with staples, put in the back zippers and door canvas
- up front attach a piece of aluminum sheeting to cover the front
- attach the lock to the plywood and bottom shell for security
- measure, cut, and glue down foam pieces to the bottom shell
- put on car, throw in some sleeping bags and pillows and you're ready for the mountains
- attach the 2 front hinges to the existing holes that are already there
- attach the 2 back folding uprights to the original holes at the top, on the bottom you will have to attach them at 90degrees and drill new holes (now you have your basic shell structure)
- close the shell and flip it upside down
- attach the reinforcing bars running lengthwise (this is to add rigidity to the bottom shell)
- align the roof rack to how you want it to sit (I spaced it evenly to distribute the weight)
- drill holes through the reinforcing bars and the bottom shell for the 4 u-bolts (it is critical that the u-bolts go through the fiberglass bottom shell, the reinforcing bars and joint the roof rack, this gives a lot of strength to the whole works)
- flip the works right side up, make a paper outline of the back hole while the 2 shells are closed, transfer it to the 1/4" plywood
- cut the back plywood and attach it to the top shell with 3 bolts
- open up the camper, attach the canvas with staples, put in the back zippers and door canvas
- up front attach a piece of aluminum sheeting to cover the front
- attach the lock to the plywood and bottom shell for security
- measure, cut, and glue down foam pieces to the bottom shell
- put on car, throw in some sleeping bags and pillows and you're ready for the mountains
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