Gladiator Expedition Rigs

[Mules]

I would think 3/4” would hold plenty of weight without sagging. How much weight are you anticipating it needing to support?

I would also ask @SloW8 what they used with their pop up camper.

I figure two adults or about 400 lbs. I think I'll add support on the front edge, as you would usually put your entire weight on this edge, when you climb in bed. When you are in the bed, your weight is more evenly distributed.

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[FitfulGoat]

I figure two adults or about 400 lbs. I think I'll add support on the front edge, as you would usually put your entire weight on this edge, when you climb in bed. When you are in the bed, your weight is more evenly distributed.

May be worth mocking up a panel to test sag under load but I would think some simple aluminum L angle could help with reinforcement in the middle of each panel with minimal added weight and complexity. I also agree that leading edge will get a lot more load when getting in and out of the sleeping area.

 

[rharr]

i would suggest pine 3/4" x 4" boards lashed together with canvas so they can be folder accordion style and stackable or rolled up. 3/4 ply seems heavy. I have the image of a foldable windshield shade screen but made out of boards.

If you are worried about strength you can still use the pine boards but add aluminum t extrusions in between every other board to stiffen it up. Then you could roll it up instead of fold it.

something similar to a camp table top but for a deck.

 

[-miko-]

I figure two adults or about 400 lbs. I think I'll add support on the front edge, as you would usually put your entire weight on this edge, when you climb in bed. When you are in the bed, your weight is more evenly distributed.

Great build. Just stumbled on it and eager to see it complete.

My $.02 for what it's worth - I like your idea for 3 separate pieces. It would let you use one or two to create a loft area if you wanted. Much more versatile. And I would brace the 48" span somehow. Initially it might hold but with some humidity and time I think you'll find it drooping. But that's speaking from experience making shelving with 3/4 ply where I never went more than 36" without support. Maybe with intermittent use it wouldn't flex as much. And the bracing could be as simple as a metal backing plate.

 

[Mules]

i would suggest pine 3/4" x 4" boards lashed together with canvas so they can be folder accordion style and stackable or rolled up. 3/4 ply seems heavy. I have the image of a foldable windshield shade screen but made out of boards.

If you are worried about strength you can still use the pine boards but add aluminum t extrusions in between every other board to stiffen it up. Then you could roll it up instead of fold it.

something similar to a camp table top but for a deck.

This is a cool idea, I've thought about. Ikea has bed slat platforms like this and Dan Brec's Ursa Minor has something similar, pictured below. I think the trick is to use a very strong wood like spruce.

 

[rharr]

or supplement it with metal and run it short ways. The photo above puts to much span going front to back, go side to side and roll it up when you want it out of the way.

good news is you can buy a few test boards, cut them to span some saw horses and load test different designs and configs.

 

[Mules]

Here's an example of 3/4" Birch.

 

[BaileyW7]

I’d build a 80/20 extrusion ladder frame with thin corrugated plastic on top. Super light weight and you can use the extrusion for gear storage mounts and hanging. Let’s you utilize all the space available in a small area.

 

[Mules]

The hatchback struts are in! They work but I'm not comfortable with the amount of pressure on the plexiglass window. The weight of the hatch was between two strut sizes and I picked the heavier one. Looks like I'll drop down to the lighter strut. Pretty easy to change out though.

 

[Mules]

Making some bracket / hinges for my pop top stabilizer. Next up bending some conduit.

 

[Jaxmax]

Be careful bending up conduit, aluminum conduit is a softer alloy to alloy it to bend without cracking or kinking. I built surf rod holders out of 3/4" aluminum conduit, and they bent pretty easy.....jack

 

[Mules]

Almost finished with the front pop up stabilizer.

 

[Mules]

No more wobbling side to side, or front to back. Top support stabilizers seem to work. A wedge design would have been a lot easier!!

 

[rharr]

can we get a video of it operating once you get the bugs worked out?

 

[Mules]

Alright, below is an example of a three piece upper bed platform. I won't need the hatch since my bed will be long enough without it. I would rather put a single piece push up bed with pneumatic struts in, but sadly, I won't be able to get to my front lift mechanism. The three piece design is simple and easily moved around.

Three options for the wood platform covering:

Clear coated or painted plywood
Automotive carpet/felt covering
Bed liner coated plywood (I like this one)

Any opinions?

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