Tags: [[automotive]] [[engineering]] [[mechanical design]] [[electronics]] # F150 Platform Camper Portfolio --- ![[20251114_134500.jpg|500]] ### Project Overview This project explores the design and fabrication of a custom, modular truck bed camper for my 2018 Ford F150. The primary driver was cost-effectiveness compared to market solutions (e.g., GFC, Super Pacific) while adhering to strict functional constraints, most notably the ability to transport my Surron electric bike upright inside the bed. ![[Pasted image 20250426203304.png|500]] ### Design Principles & Goals The "Platform Camper" is designed as a hybrid between a roof-top tent and a truck cap, maximizing utility for both camping and cargo. * **Vertical Clearance:** The critical dimension was determined by the Surron bike (~43.5" - 45.5" height), necessitating a high-roof design. * **Modularity:** Utilizing T-slot aluminum extrusion (15-series) for the frame allows for infinite mounting points and future adaptability. * **Livability:** A versatile "2nd floor" sleeping platform with a dedicated entrance. Half of the bed slides into the cab-over, transforming the truck bed into a spacious room. It can also slide in the opposite direction to serve as a standing desk or table, offering panoramic views from the large windows. Anti-condensation features (felt headliner) are also integrated. * **Security:** Electronic locks integrated with the OEM key fob system. * ### Design & Fabrication Process * **CAD Complexity:** The Master Assembly utilizes over **900 individual components**, requiring rigorous top-down design management to handle constraints, interference checking, and motion analysis for the lift mechanism. * **Reverse Engineering:** The truck bed was **3D scanned** to capture the exact draft angles and compound curves of the bed rails, ensuring a seamless, factory-like fit for the custom mounting hardware. * **Custom Machining:** Critical structural components, including the rail clamps and corner brackets, were CNC machined in-house to match these scanned geometries precisely, achieving a low-profile fit and high load rating not possible with off-the-shelf "universal" hardware. ### Technical Implementation ![[Pasted image 20250415123704.png|750]] #### Structural Frame The core chassis utilizes heavy-duty aluminum extrusions (1530 profile). * **Mounting:** A custom "low profile" clamp system was designed to secure the frame to the truck bed rails without compromising the bed's utility. * **Analysis:** Finite Element Analysis (FEA) was conducted on the clamp designs to ensure rigidity under off-road vibration and G-forces. * **Fabrication:** Corner brackets and joinery were custom-machined/cut, with specific attention paid to "cabover" clearance. #### Doors * **Security & Functionality:** The side access doors provide secure, key-locked storage for both daily use and camping gear. * **Latching System:** Custom paddle handles actuate dual-stage rotary latches. These latches allow for a "secured half-open" position, enabling crucial ventilation without compromising security or fully exposing the interior while sleeping. * **Stiffeners/Mounting:** Aluminum extrusion door stiffeners were integrated into the design, which also double as versatile mounting points for quick-access storage and organization solutions. ![[20251115_074356.jpg|750]] #### Tent & Textile Design * **Material:** Ottertex, a PVC-backed polyester, was chosen for the main tent body due to its superior waterproofing, abrasio resistance, UV resistance, and relative light-blocking properties. Its compatibility with PVC adhesives also facilitates patching and repair. This was paired with a waterproof 300D ripstop rainfly (8000mm rating). * **Architecture:** The tent utilizes a full pop-up design (not wedge-style) engineered for maximum internal volume within the truck bed footprint. This involved detailed load rating, precise gas strut selection, and a custom hinge mechanism to ensure smooth, reliable, and effortless opening and closing, significantly increasing interior livable space. * **Fabrication:** Sewing involved complex curved zippers and custom patterning for windows and insect mesh. * **Condensation Control:** Closeable vents were strategically integrated into the tent design to allow for active airflow management, crucial for mitigating condensation build-up in varying climates. * **Window System:** A versatile three-layer window design incorporates a waterproof outer layer, an integrated bug mesh layer, and a removable inner vinyl layer. The vinyl layer effectively retains heat and maximizes natural light during colder months, and is replaceable to counter fading over time. ![[_E9A6972(1).jpg|750]] #### Electronics & Systems * **Power:** Anker Solix C1000 serves as the central power hub, fed by roof-mounted solar panels on custom coroplast mounts. * **Lighting:** Programmable WLED/ESP32 based LED strips offer multi-functional illumination: customizable interior lighting, campsite lighting when doors are open, and a dedicated work light over the tailgate for cooking or tasks, all controllable via smartphone. * **Integration:** A rear-view camera was relocated and integrated into the camper body to maintain visibility. ### Cost vs. Retail By leveraging DIY fabrication (sewing, machining, assembly) and industrial materials (80/20 extrusion), this project aims to deliver a "pro-sumer" grade camper at a fraction of the $8k-$12k retail price point, while offering features like a flexible sleeping and living space, lights and power, storage flexibility, and all season performance, that commercial units often lack.