Couple Builds DIY Expedition Vehicle E2 | Aluminum Frame
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- Опубликовано: 13 ноя 2020
- In this episode we complete the aluminum exoskeleton and vinyl wrap the truck!
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We're building the ultimate adventure vehicle and hitting the road full time! Tap that subscribe button and follow along as we build an off-road capable DIY 4x4 truck camper that allows us to explore, hike, bike and ski our way through the country.
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Website: www.trailtestedmfg.com 
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We can't believe how much attention this build got. Thank you SO much for the support! 🔥
🚨 Have you checked out our final tour video? ruclips.net/video/rO6vQnjdkEI/видео.html
Dudes please pin your own comment so that it stays on top of all other comments!!!!!
I searched out your channel thinking I missed a new video. Nope, it was just me being impatient. So, now I'm going to binge your camper series.
I wanna build a low toy hauler camper, using a fwd car & a rear trailer axle. I like steel, I don't trust aluminum for structure. Basically a cube van, but no rear differential getting in the way.
I love your off-grid place. Wish your new family well.
a couple who builds together stays together cuz they build their relationship too
Although not a term often used to describe an aluminium expedition camper frame, I consider it a thing of beauty!
In particular the gorgeous wrap around nosecone, the over cab supports with their relief cut outs and the curvaceous sheet aluminium attached to the frame for the wall panels to be affixed to!
The reason that it looks to be a top tier expedition camper even at this early stage is because that's exactly what it is!
Meeting and exceeding the designs and construction standards from renowned manufacturers, this is quite simply outstanding!
The very high standards of workmanship are evident, as is the excellence of the design.
Good to see that each works in accordance to their preferred tasks, and to have so meticulously applied that vehicle wrap was truly impressive!
There's a reason the quote to apply it is so high, it's one hell of a thing to do and get right, with countless hours spent on details which may not even be readily apparent.
Then there's the preparation...
Superb craftsmanship beautiful presentation, narration, videography and editing, thank you for this lovely video.
Riley truly does have an incredible eye for design! He is able to balance form and function in a way that is both delicate and strong. I am always amazed by the result and love to help him bring it to fruition!
Awesome Sunday morning project continuation with fresh coffee. Good job on the deck, as this material I used on my deck primarily so that I never have to stain every second year. Best money spent 👍🇨🇦
Eraser tool on a drill will remove that adhesive in seconds without damaging your paint , awesome work you guys , i have been building my own stuff for a little while now and you both are an inspiration
I’ve used one in the past and it was awesome! I’m stubborn and didn’t feel like driving to the store to pick one up 😂. Thanks for following along!
Holy Crap! I am more impressed with every video! You wrapped your truck and fabricated a aluminum frame for a camper. And pro results. Our are a great team
Thank you for following along!
Electricians and metal fabricators are among the sexiest folks in my opinion specially for a homesteader.
😉
You two are great. The ideas are awsome and even the dogs all in. The gangs all here.
I’ve been a welder /fabricator for 22 years & I currently work in aerospace & I have to say you guys have skills , this is giving me inspiration to start on my own build , great videos !!!
Thank you for watching and following along. Life is short, so build cool shit!
Absolutely, you got that right!!!
I’m an engineer for a company that produces a little bit larger units on Ford chassis’ our here in Colorado. Y’all need to stop by on your travels, love seeing some of these amazing builds!
We would love to! Can you please shoot me an email with your contact information so we can touch base when we make it to Colorado? courtney@trailtestedmfg.com
Great job again guy’s. That Plasma cutter is so cool to watch. The wrap looks great, nice craftsmanship all round.
Thanks Evan!
Subbed. Amazing work so far. I love that you both are tackling multiple crafts to put this together. Job well done!
Thank you for support! Learning new skills is intimidating but also extremely rewarding!
You are two very ambitious and talented people love it!
Thank you!
Beautiful craftsmanship!
Very nice job both of you. They sell rubber wheels for your drill for removing decals. I had to remove stripes from the length of a truck and it was the only tool that made it tolerable.
That would have sped things up!
One of the best DIY series I've seen on the youtubes, both in quality of the work & video production. The music gets a little overwhelming at times, but that may just be me. Well done guys. Now I wanna go camping in that thing.
Thanks so much Frank. I really appreciate the feedback!
To remove the table sided tape for the badgers and body (As a Panel Beater) I use a little rubber wheel in the drill and it removes it quickly and nicely.
Great tip. I’ll have to look into that next tome!
Courtney Casey Just be carefully what type of rubber you use. 3m do sell them. And there cheap.
It is wonderful to watch all the excellent quality of workmanship achieved ,I just enjoy this every steps of the build ❤️
Thank you for watching Michel!
super rad. I want to build one of these eventually probably on a straight truck/ u haul type box frame.
One suggestion for the wrap is take the door handles off! makes it much easier and then you can tighten the handles down on your wrap and makes it extra safe from peeling up
We actually started to take the door handles off, it wasn't a simple task on this Ram and we decided it wasn't worth the effort, time, and and potential future door rattles. Thanks for the recommendation and glad you liked the video!
I'd love to have one .... amazing job
Thanks Neil!
Sprayt the badge glue with WD40 and leave for a few mins, then it will rub is nice and easy.
oh my gosh are you crazy... i am so jealous of ur skill and ur teamwork good job man...
Thanks for watching Joe!
Beautifully done...😍
Thanks Teddy!
You are building the camper I’ve dreamt of building. And it didn’t look half this pro-built. A CNC plasma table in your garage? Are you kidding me? This I have to watch. Not sure why you didn’t come up in my feed before. Subscribed. Thanks for sharing!
Thanks for subscribing and following along. If we can fit a plasma table in our garage, so can you! 😉
If you ever develop a pre-cut kit for the aluminum parts that can be flat packed on pallet let me know. I’d be interested in a Jeep Gladiator version!
Or-for ease of working on the road during your travels would you consider developing cut lists for sale that can be taken to a local shop for processing? I’d have to believe I’m not the only customer you’d have for something like this.
@@dmwi1549 We will keep that in mind!
Very cool build. I’ll be following along! Thanks!
Thank you for supporting us!
T rey
@@AmbitionStrikes rtyrt s try
I really like your videos and the process details and explanations as well as your testing of your panels. I am considering a similar build but have struggled with using welded Al6061-T6 as an exoskeleton. This is because 6061-T6 gets its strength by relatively low temperature heat treatment known as "artificial aging". When you weld this aluminum your filler metal does not get the same heat treatment so is lower strength than the surrounding material. More critically, the heat affected zone next to the welded area "overages" and strength drops to less than half of the original strength. Flexing of this structure during regular driving and in particular off-roading will mean that failure will occur due to fatigue cracking along the heat affected zone. I have seen welded 6061 aluminum trailers fall apart after 2 years of use. The good news is your design has the joints exposed so you will see it when cracks develop and you may be able to repair the cracks. You may be lucky and delay cracking for several years with the sturdy panels you have built so good luck! One other detail that your mention in passing but I did not see in detail is the mounting of your aluminum structure to the steel frame. You mentioned a spring system to mechanically isolate the structure from the frame. These should also be electrically isolated to prevent "anodic" corrosion of the aluminum at the points of contact. Take care and I look forward to your other videos!
Thank you very much for the detailed and thoughtful comment! Our exoskeleton is made from 5052 for formability, the sub frame is 6061-T6. We are well aware that welding the aluminum created a heat affected zone and therefore stress concentration. Our thinking is that the panels will support those joints and minimize the fatigue. Luckily all of the welds (including the sub frame welds) are visible and we will be able to inspect them periodically. The spring system does not mechanically isolate the structure from the frame. The front of the camper is rigidly bolted to the truck frame. In the rear, the springs clamp the camper to frame so that if there is a situation where there is significant truck frame flex the camper is able to separate from the frame in the rear and (hopefully) limit the torsion being transferred to the camper. The subframe contacts the truck frame at 10 points to distribute the load over a large area of the sub frame. The camper is grounded to the truck frame with a heavy ground cable. Do you think this is sufficient to limit the electrolysis? Either way this will also be periodically inspected.
@@AmbitionStrikes Wow! Thank you for your thoughtful response. I am a materials/manufacturing engineer and usually my questions/comments are blown off. Your response shows that you understand the issues of using aluminum and your willingness to to engage is what I think RUclips users should embrace to help viewers understand that there are always trade-offs when you are deciding between different materials.
With regard to the contact between aluminum and steel, the electronegative potential of aluminum is greater than that of steel so that means it will form the anode in an corrosive environment resulting in it corroding at the points of contact with the steel frame. There are a number of factors that affect this type of corrosion (electronegative potential, the surface area of the two metals in contact, and an "electrolyte" to allow the electrons to exchange). In your case it appears that you live in a dry area so I expect little corrosion would occur. In my case, I Iive next to the North Atlantic so I would absolutely have to isolate the aluminum from the frame. A friend mounted a light bar on his new Jeep and the cast aluminum case corroded thru in 12 months. I also noticed in a later video a discussion about a stainless steel screw snapping off after it had galled... this shows you folks really know your materials. I study galling of stainless steel and I hope that your viewers appreciate your depth of knowledge in working with metals. It is a great pleasure and inspiration to view the progress of your build! take care and I hope one day we cross paths!
Wow! Wish I had all the skills...and tools
Only one way to learn! 👊🏻
@@AmbitionStrikes Great job! It's looking very cool.
Dental floss takes the badges off and then you could us one of them decal remover and would be easier.
I didn’t want to stop working to go pick up a 3M adhesive removal wheel but it definitely would have made things go quicker! 🙈
Totally digging it!
Thank you!
Man i need a bigger plasma table .... Nice work
Thank you! We almost did a 4x4 because of space concerns but are VERY glad we decided to upsize.
I know I came along a little late, but if you use a stainless steel brush (use only on your Alum.) and clean it, you will have better welds (less black). I'm amazed with what you have done, I somehow started on part 7.
Yes we have a brush (labeled aluminum only 😉) and use it before welding, thanks for the tip! And thanks for following along!
So freaking good looking camper truck, looks so pro, love it!
Thank you!
Parabéns! ..amazing job.
Thanks Marcelo!
Outstanding job, guys!!
Thank you!
Another great video. Keep them coming!
Thanks Andy!
Lighter fluid will take that rubber tape off very quickly.
This build is coming out amazing! Are either of you engineers by trade? Or are yall self taught fabricators and designers? The vinyl came out awesome and you saved big time! I would be thrilled if either of you did a detailed video on the fabrication or how to do vinyl yourself. Great Job!
Riley has a degree in manufacturing engineering and we started our business together right after college! All of our fabrication skills have been self taught, starting in college with joining the off-road club. I will definitely consider doing a detailed video on the vinyl wrap!
@@AmbitionStrikes That is awesome, Yall do great work and I look forward to the rest of the build. I don't have a engineering degree so I will be watching very closely haha. Plus the big reason I never got a vinyl wrap was I was under the impression you had to have special tools and chemicals to apply it. So I look forward to anything you can show on the subject.
@@AmbitionStrikes how well does vinyl wrap last? Especially off-road. Does it need constant repair / maintenance?
멋진 캠핑카 응원합니다😊👍👍👍"
Thanks!
Congratulations
Thank you!
Good idea
Thank you!
Man, woodworking is a huge hobby of mine, but I wish I had the talent for metal work
Only one way to learn!! 👊
Enjoying your Project videos . Pretty sweet build!
Thanks for following along!
@@AmbitionStrikes Wonder if you considered Raptor Liner the whole rig instead of a vinyl Rap? Great product , user friendly , Tintable, and you get that " Dope Bro" comments on the road & at gas stations. I did my truck , and will probably do my camper/ boat next until I may one day get the opportunity to built something as cool as this ;)
It was considered but I decided it was too permanent of a solution for a vehicle we plan to sell eventually. With vinyl the future owner can still restore the truck to the factory paint!
@@AmbitionStrikes Yes, the beauty of vinyl , is you can peel it off 10 plus years later, and basically have the original paint finish .
Truck looks good. Good wrap.
Thank you very much!
Is there somewhere you go over more details about the frame structure?
Looking to build something similar but having good things to reference would be nice
Coming along super good. Really taking shape. So you rent out the house your remodeled for extra cash? Great idea. If I didn't have so much stuff, I would totally do that. Pretty penny. Thanks for sharing.
you are very good at what you doing!
Most of the time it feels more like stubborn than good! Thanks for watching ☺️
Beautiful!
Can you tell me what type of Aluminium are you using and what is the thickness of this frame.
The exoskeleton is 5052 aluminum that is .080. The subframe is .125 6061.
Hi guys, I just came across your RUclips videos and I love it, your journey is amazing! I see number of times you use a design application to build things, can you tell me what app you use to design and build your projects please? Thank you and all the very best guys!
Good job ✌️🙏nice
Thank you!
Awesome build, let's join up and manufacture them.
Feel free too shoot us an email with what you had in mind! Courtney@trailtestedmfg.com
So good job
Thanks Pedro!
I had to cover my ( blue) volvo 770 with white vinyl in 2001 to avoid painting it. I had loved my blue truck and I was thinking that I would just peel it off if I didn't like the company I was running with, turned out I liked the company( united van lines) and stayed with them 14 years, the vinyl was looking bad after about 8 years so I did peel the thinned and sun damaged thing off( pain in the you know what) and hand painted the truck with white rust-oleum 🙂
I do not look forward to the removal of any vinyl, especially an entire vehicle! 😂
@@AmbitionStrikes it was a torture, for me and my wife🙂🙂
the sticky stuff... you can easily take them off using lighter fluid (dont light it up)
Thanks for the tip! I’ll make sure to keep Riley and the matches far away... 😉
For removing stickers use break cleaner!
Holy crap this is amazing work. I just built an offroad style teardrop and the learning curve was massive. This is incredible.
One question I have though is why you didn't opt to use ambulance style frame extensions so your box could be just a little bigger?
Thank you! There were a lot of things we could have done to make the box slightly bigger but we really wanted to keep it as absolutely small as possible for maneuverability, visibility, etc. It was a really fun design challenge to fit everything in such a small space (it's exterior dimensions are smaller than a Lance 825).
Great job!
Thank you!
Great!
Thank you!
Great job!!
Thanks Paul!
A couple questions:
1. How much aluminum is overlapping the panels. The flat aluminum that tacked to the 2x2 support structure. That you rivet the panels too.
2. What is your spacing for the rivets.
Thanks
holy. awesome ! you are the best DIY ! may i know how much it cost ? cat your guys to build one
Thank you so much Ben! We are going to be doing a cost breakdown video very soon!
yay
😊
Love the camper, I love the look, Could you and Would you build one on my 06 Dodge Thanks
All we have on our mind right now is hitting the road... so maybe hit us up in a year 😉
What kind of welder/spoolgun are you using?
You can see in the video that it’s a Miller millermatic 252 and that’s a Miller spoolmatic gun.
Goooooooooooooooooooooooodjob!!!!!
Thanks!
Thanks for all the information you put in the videos. Nice to see both of you working together . Great job of getting done in 2 1/2 months . What size and where did you get the wrap?
Thanks Joey! The vinyl was purchased through Feller's and I believe we bought 50 yards of the 60" wide roll.
I've watched all of your videos on this build, but I don't remember seeing how you attached the camper to the truck frame. I know you have to take into consideration the flex of the truck frame against a rigid camper box and I've seen several methods of allowing for this, but I'm curious as to which method you all used. I'm planning a similar build and attaching the camper to the truck is my main worry right now. Thanks in advance for enlightening me!
Hi Shane! The camper is hard mounted to the frame on the front and the back is mounted with springs to allow for flexing!
I need cnc draw..I love your trucks :)
Thank you!
How was the gun for aluminum?? I've looked at them for ever.
great idea, beautiful framework....how thick is the frame and wall panel? i'm from Indonesia
Hi! The wall panel aluminum is .050, the frame tubing is 2x2 .125 and the skeleton framing is .080!
❤❤
wow
Thanks for watching!
@@AmbitionStrikes You two are amazing
Nice job following
Thanks Ken!
what if you were to do the "upside down welding" by pulling it off the truck, flipping it over, and welding "right side up?"
It was discussed! But the logistics of doing so without a forklift, and Riley's ability to weld at crazy uncomfortable angles meant it just wasn't necessary for this project.
How did you guys attached the forward part of the camper on to the truck? How about the rear side? Does it need a fixed attachment point or should there be flex or movement for it? Love you channel! :D
That’s awesome & that’s awesome & that’s awesome.
#PradeepSinghNain
Thank you so much!
Would you be willing to sell plans to your frame work? Cad or anything? Love this idea looks great!
Thank you! Shoot me an email and let’s talk! info@trailtestedmfg.com
NEXT TIME
You need to remove the badging off of your truck .......
Try
Dental Floss
&
To remove the GLUE
that was left behind from removing the badges.....
The BEST product for you to use
is called
GOOF OFF.....
You can find it at any big box store...
Thanks for the tips Anthony!
Looks so nice. Thickness you use for aluminum sheet and structure tube?
Great. What type of welding machines are you using?
Love your channel and binge watched this build. Absolutely amazing attention to detail. I built a off-road teardrop using the same monocoque technique and wish I had splurged for a pneumatic caulk gun for the sikaflex. I still have bruised palms from the manual gun! Anyway, I’m designing a pcor tray and atoverland atlas hybrid for my ram 1500. Did you find any cad models or dimensions for the truck chassis and mounting points? I’d love to know more about the subframe and mounting.
We are very glad someone recommend the caulking gun, or we would have been in the same boat as you! The only cad model we could easily find of the truck wasn't accurate enough for anything other than initial renderings. However, there are ways to access files through SEMA's tech transfer program if you have an in with a company that subscribes. Riley recommended also checking the up fitter manual!
Ok I'm a little mistfide why the vinyl wrap other than to change the color?
The vinyl will also do a great job of protecting the trucks paint when off-roading!
How do you handle warping when you weld the bars together? is it better to limit the weld spots to two points structurally. Are there other techniques to weld?
There was some warping that had to be dealt with but careful control of heat can minimize it.
Oh man.....if you don't put some supports under the extension over the cab, the bottom is gonna start to bow.
We did have some bowing issues with our panel and added supports a few weeks ago!
Where did you guys get the vinyl wrap? I’ve been wanting to wrap my truck a different color too!
What thickness did you go with on the frame? Looking at building an offgrid trailer but making the frame out of steel. Keep up the great work. You guys are an inspiration and are killing it!
The subrame is 2x2 .125 aluminum tubing and the exoskeleton is .080 aluminum!
Hi Courtney, what kind of film do you use instead of paint?
I used Avery vinyl!
Hi. What is the length and width and height of the cab over?
The sleeping cabover portion tapers from 7' to 6' wide, is 6'8" long and 36" tall inside.
Were could I get aluminium pieces like that I could cut to my dimensions?
is the camper to the frame 2"x2" square tubing?
Yes it is.
Fine job on your build here, have watched all your episodes on process and read through questions and answers. Could you help with a little more info, on the angle upper frame, you guys mention using .080 5052. What length were the legs of the angle they look to be maybe 1.5"? Also you mentioned in comments you used closed rivets, were these aluminum? What diameter and lengths did you mainly use? Thanks, i enjoyed your videos, each were packed with info and tips, greatly appreciate your sharing your experiences.
Hi Ronald! On the external frame they are 3" and on the internal bracing they are 1.5". The rivets used are 3/16" diameter aluminum and called "multi-length" so they worked on a large range thickness.
Thanks for this response, have continued to view your episodes, can't remember seeing a better presentation. Looked at #2 again last evening. Tried to see more detail on Aluminum frame by blowing up video, but had a question. I have been unable to find 5052 .080 angle from my main aluminum supplier (Reliance Metals). I may have to go to a .125 or .25 to get the 3" legs. After inflating pic, looks like the ext corners may have a stiffener plate of some type in the corners. Is this correct. Also i liked your radius on the top corners intersecting the horizontal angle. Did you start with something larger than the 3" angle and machine the radius or possibly insert a weld in Radius component ? Not sure if there is a site you might be have pics of more details of metal joints. Once again thanks for your info and taking the time to create your videos. Thx Ron
Wow, very impressive, do you guys do fabrication for a living? Is that a CNC plasma cutter you use to cut your metal? How about the 3D cad is it Solidworks?
Thank you! We started an off-road shop out of college and self taught ourselves to fabricate. We got into flipping houses a few years ago and keep the fabrication more as a hobby now. Our CNC plasma table is from Arclight Dynamics and it was the best investment we have ever made! Riley does all of his design work in Solidworks, good eye!
You two are a joy to watch and rather inspirational as well. You are very meticulous on your workmanship and rather creative and logical. Did I guess right about you using Solidworks? Did you teach yourself 3D cad as well?
@@SparkedInnovation Yes you did guess right about Solidworks! Riley learned how to use it in school (he is a manufacturing engineer).
Courtney Casey Ahh, Courtney, now it makes sense about his fancy techniques, equipment and talents. He could probably make these for a living. I wouldn’t be surprised if Riley starts making some of his parts with a 3D printer next ;). Great channel and great job guys!
What model CNC cutter is that. I want one!! LOL
We have had Arclight Dynamics 4’x8’ table for 4 years now and it is a game changer!
heyy love your stuff. where could i get the specs/ dimensions of the cage?
Very 10!
I dream of makink one like this.
Do you have the project?
Thank you! We do not have plans available at the moment.
Hello Greetings from Europe! It would be kind to tell me, how does it come, that you have CNC cutter for Aluinium? Did you buy this extra for this projecct? How much does such a CNC cost? Thanks and als Thanks for the inspiring video!
Hi Jonny! We bought our plasma table from Arclight Dynamics several years ago and they have several options so I am not sure what they are charging these days. I would definitely recommend their product!
so funny you are new at this game
Thanks for watching Doug!
@@AmbitionStrikes i really enjoyed watching your build.
NICE!! Subbed to follow along on your build. What brand is ur Plasma table? I was thinkin about building my own but....time...ya know
Edit: nevermind....found a previous response bout it
Thanks for subscribing! We considered building our own but ended up going with an Arclight Dynamics table and have zero regrets. Their customer service means we have never had a day where the table didn't work.
Sorry if this was addressed (can't find it), but did you heat-treat the frame after welding or do you think it won't be needed based on design?
Hi Ryan! Thanks for watching and commenting. Based on our design we did not feel the need to heat treat the frame.
HEY GUY AND GAL, IVE BEEN WATCHING AND REWATCHING YOUR VIDEOS TRYING TO ABSORB USEFUL DESIGN AND CONSTRUCTION INFO. PURCHASING MY TRUCK CHASSIS IN THE NEXT WEEK.
WOULD YOU PLEASE TELL ME HOW WIDE YOUR BUILD IS?
HOW LONG IS THE AREA FOR YOUR BED THAT OVERHANGS THE CAB?
BEST WISHES,
P.S.
I STILL WANT TO BUY THAT SOLIDWORKS PARTS AND ASSEMBLY FROM YOU FOR THIS BUILD.... IT COULD BE PRIVATE.... NOBODYS GONNA KNOW....NO ONE WOULD KNOW... HOW WOULD ANYONE KNOW? NOBODYS GONNA KNOW. HOW WOULD THEY KNOW.
Thank you! The camper itself is 8' long and 7' wide. The bed overhang area is 80".
No models available at the moment but maybe in the future!
Is aluminum 8020 or 4040 is to small for framing?
We don't have any experience building with 8020. I do know that it is significantly heavier and more expensive than what we used (our subframe is 2x2x.120 square tubing and our exoskeleton is .080 sheet metal).