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I was able to find all the styrofoam I needed from construction dumpsters. Furniture stores also throw a lot of it away. And yes, I used fabric, Titebond glue and paint for the outer covering. There are lots of how-to for that, just Google "poor man's fiberglass".
I used 2 x 2's. But it's much cheaper to rip your own with 2 x 4's and a table saw.
I custom built the frame to fit the truck, so there were no plans. I used 16 inch centers for most of the framing just like in a house.
The camper is bolted to the sides of the truck bed. It can easily be removed by just unbolting, provided there are 4 or more strong helpers. I have since sold the truck with the camper so I can no longer take measurements. I'm about 5'5" and the bed was about that long. A taller person could sleep diagonally though.
I don't know what the laws might be in Canada or Australia but here in Alabama pretty much anything goes as long as the lights, turn signals, and mirrors are in working condition.
The truck capacity is 1000 pounds and the camper weighs less that 400. I haven't had any issues with the vehicle handling. I once carried a Bobcat scoop of gravel (about 3/4 ton) in the bed and it sat considerably lower, was a bit uncomfortable to drive.
I didn't make any plans when I constructed the camper, just built it to fit the truck bed. I used 3 inch screws to connect the frame members and with the plywood glued to both sides it was quite strong.
I made a panel to extend the door to the bed of the truck. It was attached to the door with wingnuts for easy removal. Sorry but I don't have any photos of that, and have since sold the truck and camper.
I used 1 inch thick treated deck boards between the camper ant the truck bed. Then drilled 5 holes on each side and fastened with 3/8" X 2-1/2" bolts and large washers.
4 feet, the width of the plywood covering. I allows for 6 feet headroom inside the camper.
The camper, including the microwave, air conditioner, and mattress weighs about 400 pounds.
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It's been well over a year since the camper was constructed, no leaks have occurred. The fabric is still tightly glued to the plywood and the paint has no cracks. It's never been under any kind of cover has endured many rainstorms that are frequent here in North Alabama. There are many articles on the web about "Poor Man's Fiberglass", just do a Google search.
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I can't see where it would cause any issues. There would be no need to remove it for any of the things you mentioned, at least on my truck. All of the maintenance would be performed outside the bed of the truck.
Since the truck is a few years old and I don't intend to remove the camper unless I have to for some unforeseen reason, I just bolted it to the truck. I used 3/8" X 2-1/2" bolts, 5 on each side. I'll post photos here this weekend. You could also use clamps if you don't want to drill holes in your truck. Just search for "clamps for truck caps" on Amazon.
Cab-over Camper for PickupView Instructable »