How I Built Out the Dream DIY Adventure Truck Camper

This article details the process and rationale behind building a customized, four-season, ultralight truck camper using a Total Composites shell. The author, having tested various adventure vehicles and campers, decided to embark on a DIY project to create a rig that perfectly suited their specific needs for cold-weather camping, hunting, and skiing in the Rockies, addressing shortcomings found in commercially available options. The core of the project began with a Total Composites Truck Camper shell, specifically the Wolf 6.5 model. These shells are lauded for their construction from polyurethane foam sandwiched between fiberglass layers, resulting in an incredibly well-insulated, lightweight (795 pounds before windows), and durable structure. A key advantage of this construction is the absence of internal framing, which eliminates thermal bridging and subsequent condensation issues common in poorly insulated campers, making it ideal for sub-freezing temperatures. The author outlines the decision-making process, highlighting the desire for a self-contained unit that offered off-road capability, comfort, and the ability to cook and relax indoors during long, cold nights, without the burden of towing a trailer or the high cost and maintenance of a full-size van. The choice of a truck camper also offered insurance benefits, as it's typically considered cargo. The interior build-out, a significant undertaking for someone with limited carpentry experience, began with planning the layout using SketchUp, a 3D modeling program. The chosen layout prioritized maximizing floor space for occupants and two dogs, placing the galley and essential systems (batteries, plumbing, stove) against the front interior wall. This design strategy helped distribute weight optimally and simplified the construction process. Cabinetry was constructed from 3/4-inch Baltic birch plywood for its lightweight, strength, and aesthetic qualities, secured using Korapop adhesive and screws into reinforced fiberglass corners. Essential tools included a cordless drill, impact driver, saws, and wire crimpers. The article then delves into the installation of four critical systems: electrical, water, heating, and refrigeration. For electrical power, two Battle Born 100 amp-hour, 12-volt lithium batteries were chosen for their full discharge capability, longevity, lighter weight, and self-heating feature for cold weather. The Redarc Manager30 system was used to manage power from various sources (AC, solar, vehicle alternator). Lighting, pre-wired into the camper shell, was connected via a switch and fuse block. A 200-watt Redarc solar panel was mounted on the roof for charging. The water system consists of two seven-gallon Reliance Jumbotainers, retrofitted with a Shurflo water pump, allowing for easy filling and removal. Flexible tubing connected the components, and a simple switch activated the pump. Gray water is discharged directly outside for boondocking with biodegradable soap, with the option to use a tank for containment. Hot water and cleaning needs are met by a Geyser system, a portable camp shower that heats 2.5 liters of water and provides a 15-minute sponge bath. Heating was addressed by installing a Wallas Nordic DT, a diesel stove and heater combo chosen for its dual functionality and compact size. This unit, commonly used in marine and Sprinter builds, fit into a countertop cutout and uses a small exhaust and fuel line. It operates as a cooking surface with the lid open and a heater with the lid closed, featuring a high-altitude mode for reliable operation. For refrigeration, a Dometic CRX 80 under-counter electric fridge was selected for its efficiency and ability to keep food cold for extended trips. Finishing touches included a Hest Dually Long mattress for the cabover bed, an EZ-Reach dining table system that swivels and tilts for versatility, and custom-ordered bench seat cushions. Flooring was a simple outdoor rug for comfort and easy cleaning. Storage solutions included a tall cabinet, Ikea racks, storage nets, and a PakMule cargo carrier with a "Porch system" on the truck's hitch for external gear. The author also upgraded the truck, a 2018 Tundra, with Toyo Open Country ATIII tires, Firestone RideRite Airbags, Daystar Cradles, and an ARB/Old Man Emu BP-51 suspension kit to handle the camper's weight and improve off-road performance. The article concludes by highlighting the satisfaction of camping in a self-built rig, the flawless performance of all systems, and the advantages of the chosen design, such as easy setup, maneuverability, and off-road capability. While acknowledging the project wasn't a budget build due to high-end components, the author notes that the Total Composites shells offer a customizable foundation for various budgets and skill levels, providing a fulfilling DIY experience or the option for professional upfitting. #DIYCamper #TruckCamper #AdventureRig #OverlandBuild #TotalComposites #OffRoadCamping #FourSeasonCamper #CustomBuild #VanLife #DIYCamper #TruckCamper #AdventureRig #OverlandBuild #TotalComposites #OffRoadCamping #FourSeasonCamper #CustomBuild #VanLife