DIY hardtop camper shell

[OKStingRay]

I have been wanting to get a camper shell for awhile now. I Just have not wanted the price tag that comes along with them. I want something heavy duty for a possible roof top tent build later this summer. So I found a 25 dollar s10 camper shell on Facebook market place and began to chop with a goal to keep this under 1k.

The plan is to shorten the frame, reuse the bed rail, front and rear sections, and the doors and window. Then use 3/4 plywood on the sides and 1/2 for the roof, reinforced with some 2x4's.

I have an old surco 45 x 60 roof rack basket sitting on an old XJ and will be using that. For the mounts I will be using some heavy duty 2x4 trailer stake pocket brackets. I will be spacing them out evenly 4 per side for my cross bars.

My main goal for this build is strength and functionality. It's not going to be winning beauty pagents, but im hoping I can make it look clean. I am coating everything in magnet paint's chassis saver and then black monstaliner.

Pictures coming soon.

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[Figmo]

sounds like it's gonna weigh a ton. looking forward to pics.

 

[OKStingRay]

sounds like it's gonna weigh a ton. looking forward to pics.

Yeah it is going to weigh a bit more than I'd like. But the S10 camper shell I found came with very large doors so there isn't going to be very much 3/4 plywood. I also ripped the 2x4s down some to save some weight. Trying to figure out how to post pictures now.

 

[OKStingRay]

 

[OKStingRay]

I should have the roof installed today. Then I will be rounding off the corners and edges and filling in the cracks and such with wood filler. Then It will paint prep and waiting for it to get here. Going to be about 12 hours or so worth of work when finished and around 600 bucks.

 

[OKStingRay]

 

[Figmo]

I think it's looking good.

I hope you glued and screwed all those joints. There's gonna be a lot of lateral forces pushing and pulling this thing apart from every conceivable angle. (And probably a few you would never conceive of LOL)

 

[Idlethunder]

Do you know the name of the company that made the original S10 shell?

 

[OKStingRay]

I think it's looking good.

I hope you glued and screwed all those joints. There's gonna be a lot of lateral forces pushing and pulling this thing apart from every conceivable angle. (And probably a few you would never conceive of LOL)

Yes everything was glued to oblivion and back. And most everything is screwed from the inside going through the aluminum tubing. Everything screwed from the outside has already been covered up with wood filler and sanded down so you can't see much.

 

[OKStingRay]

Do you know the name of the company that made the original S10 shell?

Sorry, I'm not sure. I looked when I bought it and didn't find any markings anywhere.

 

[OKStingRay]

Roof was just a bit too wide for a full sheet of plywood, so I had to make a little T joint out of a 2x4. Coming together pretty well. I can easily put it on the jeep myself for now. Bed liner will add a bit more weight. Luckily the doors can easily slide off their frames so I can remove them while I install.

 

[professorkx]

Love seeing these kinds of DIY projects!!!

 

[OKStingRay]

Love seeing these kinds of DIY projects!!!

Your jeep in your profile pic may be the coolest I have ever seen. I am EXTREMELY jealous. Makes me want to get my willys pickup put together.

 

[HorsesRear]

You do nice work.

 

[professorkx]

Your jeep in your profile pic may be the coolest I have ever seen. I am EXTREMELY jealous. Makes me want to get my willys pickup put together.

When my wife came out to my shop and saw the 47 in this condition after some work with a sawzall , she knew I would be spending more money and time on another project, but is always in total support of these kinds of projects. A year later, we took the 47 for its first drive as a truck.

I get a lot of question from hard core Jeep folks wanting to know what model Jeep I have, as they have never seen one before…it’s one of one.

As I noted, I love quality DIY projects…everything doesn’t need to be bought off the shelf.

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