My Truck Cap DIY

From Goat Carrier to Camper - The Possibilities are Endless

I moved to Alberta in a 1987 Dodge B250 Camper Van. Lovingly named ‘Ugly’, I only used it for one trip to Fort Mac, where I promptly got to work and never stayed in it again. Years later while doing a course in Calgary a classmate living in the back of her truck reminded me of ugly. I loved living in the back of the old van and have wanted to build a tiny camper ever since.

Aptly named, Ugly was awesome.

Plans and Schemes

When I began to plan my departure from Fort McMurray, I wanted to build something in the back of a Ford transit van. A full-size transit makes a comfortable living space, but the Transit Connect has incredible mileage. Though very small, I often considered the smaller option so that I could go farther on adventures. Canada Post uses them and I often see them zipping around making deliveries.

‘Babe’ the Tacoma

Within the first week after we bought ‘Babe’ the silver Tacoma I started scheming how to build a space in the back. I wanted to make it light and modular so I could put it on and take it off on my own. I thought I’d have to build it entirely out of wood, so that was going to be tricky.

The Roof Rack

When I can I wait for things to materialize on their own. Though it took a couple of years, the opportunity for a lightweight rack for a steal of a deal came up - and I had to have it. Made of aluminum and an exact fit for Babe, it was the ideal framework to build a small camper/goat carrier.

My old goat carrier, made out of repurposed pallets was destroyed by last winter’s snow. The new roof rack came at just the right time. Shortly after getting it, I needed to take a goat to town. Out of necessity, I began building the sides out of 3/8 plywood.

The Design

I kept things simple and light. To start I cut square pieces for the sides and drilled holes into the frame to attach them using wood screws. Don’t use wood screws to attach plywood to aluminum! This was temporary until I could get my hands on some bolts.

Next, I made a frame for the back with a door wide enough to step through. I kept it within the tailgate so that it could be locked. For the roof, I made notches so that the plywood slips into place sideways. It would be hard-pressed to come out even without fasteners.

After using it for a couple of trips with goats I decided it was time to stain, paint and add some windows. While I had the sides off I used a Rivnut gun to make threaded holes in the frame. That way I could re-fasten the plywood sides quickly and properly.

I cut the window holes 11X11 inches and drilled holes into 12X12 acrylic glass to attach to the insides. I debated with myself about how to attach the glass, knowing that if I attached it to the outside it might find a way to blow off in extreme weather. Since I am by no means an expert woodworker I decided to err on the side of caution and put them inside.

The back door however got a slider! I made wood tracks for the acrylic glass to ride in and a latch at the top. Not my best work but I can reach through the window and close the tailgate.

Future Plans

Mattress: Though the 6 foot box in ‘Babe’ fits a twin mattress, at the wheel wells it’s a bit narrower. In the future, I plan to trim a foam mattress to fit perfectly.

Opening Windows: One of the reasons that I like to do these projects slowly is so that I can make adjustments as I get new ideas. I wanted to have opening windows on the sides but couldn’t think of a safe way to do it, until the other day when I realized - I could hinge the whole plywood side and flip it up! I’m excited to add the new modification when I get a chance.

Waterproofing: Getting the plywood to be waterproof isn’t that tricky but figuring out how to seal the gaps is another story. Keeping it removable is important to me, but the grooves which allow me to put the top into place let in water. Some sort of a gasket material, maybe?

The Short Tripper

Keep in mind that Babe’s cap is for short trips. For longer trips, I have a beautiful Toyota Slumber Queen. After buying it, my road got a lot more rough and I’ll have to do some work to it before I can take it out again. For now, it serves as ‘the guest house’ but someday I hope to take it out for some epic adventures. In the meantime, Babe’s plywood cap is fulfilling my dreams of building a small truck camper.