Roof Top Tent

Design and build a custom roof top tent to emulate the iKamper SkyCamp 2.0

Goals and Requirements

  • Queen sized bed

  • Fully waterproof tent

  • Hard shell to allow for mounting equipment

  • Easy and quick to set up and tear down

  • Visually appealing and not obviously DIY

  • Slim profile to reduce overall vehicle height

SkyCamp 2.0

SolidWorks Design

Completed Version 1 Latched Closed


Completed Version 1

Design Considerations

  • Boat builder epoxy resin to fully waterproof outer surfaces

  • Only SS hardware to reduce and corrosion in weather

  • Strengthen unsupported overhangs with aluminum L-channel

  • Rough industrial-type carpet tiles allow for slight airflow beneath mattress, preventing moisture buildup

  • Slight contouring and fillets for the shell to reduce the appearance of just being a big wooden box

  • Add elastic seam to help prevent the heavy fabric from drooping

Lessons Learned for Version 2

  • Design the fabric shape in SolidWorks and use "Flatten" to produce a sewing pattern

  • 600 denier canvas is extremely thick heavy

      • Very difficult to sew through multiple layers

      • Minimal stretch of polyester causes fabric to droop, may lead to rain collection

      • Difficult to tuck inside for closing

  • Velcro is not ideal to use for mosquito netting

      • Removal/installation is not quick and easy

  • Position and orientation of the gas springs does not allow for the desired minimal force to open

      • Version 2 re-design allows for longer springs to fix this

  • Plain hinges do not leave enough of a gap for the memory foam pad even when fully compressed

    • Version two hinges allow for a larger gap between base halves when closed, allowing the foam to remain inside when closed


Full Build Process


Structure Materials

  • 3/4" common board for shell

  • 1x2" common board shell inner structure

  • 5/16" plywood for the shell upper surface

  • 3/4" Plywood for the base

  • 1/4"x3 Plastic Trim

  • Aluminum L Channel

  • Aluminum Flar Bar

  • Marine Epoxy

  • Bucket of Wood Flour

  • 8.5 ft Aluminum Telescoping Ladder

  • Aluminum Conduit

  • Heavy coated SS hinges

  • Misc SS hardware

  • 5' SS piano hinge for the rear hinge

  • Weather Stripping

  • Toggle Latches

  • 60lb Gas Springs

  • 24" carpet tiles

  • Paintable Caulk

  • Filler Primer

  • Spray Enamel

Sanded Hard Shell




Hard Shell Prior to Sanding

Marine Epoxy Layers for Weatherproofing

First Coat of Primer, Before Filler Primer, Sanding, and Trim

Build

  • Build main shell structure from plywood and common board

  • Add edge fillets

  • Strengthen joints and fill imperfections with putty made from epoxy resin and wood flour

  • Sand all surfaces

  • Add coats of epoxy to all wood surfaces

  • Many layers of primer, sanding, and enamel

  • Join shell and base with SS piano hinge

  • Heat form the plastic trim to follow the contour

  • Flatten Aluminum Conduit, cut to size, and attach at the desired angle with small hinges

  • Attach ladder with hinges

  • Use adhesive to add carpet tiles

Full Test Fit




Test Assembly




Version 1 Tent Materials

  • 600 Denier Canvas

  • Selric UV Resistant Thread

  • Heavy 40" Zippers

  • 1/2" Wooden Dowels

  • 1/2" SS Lathe Screws

  • 1/8" Elastic rope

  • Gear Aid seam sealer

Starting the Sewing Process

Process Summary

  • Lots of trial and error

  • Cut main sections to size and use half flat felled seam to connect

  • Drape the piece over the frame and mark where seams should be

  • Cut corner panels to size and add to main body

  • Sew main door flap with Vislon zippers

  • Cut windows flaps to size and and attach to main body

  • Add triangular vent flaps

  • Add wooden dowels inside door and window bottom seams to add rigidity

  • Add grommets to windows and doors

  • Add loop and toggles for windows and door

  • Use hot glue to adhere velcro for the mosquito needing around doors, windows, and vents

  • Add 3" skirt around the entire base to help deflect water

  • Attach to main structure

Finished with Rolled Up Flaps

Test Fit for the Shape

Finished with Closed Flaps

Version 2 Coming Soon