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Phase 4

The next stage is working out how to construct the habitation box for the back of my truck.

Construction options

Where do you start?

There are many ways to construct the box, here are some examples of the most common methods.

Wood

Metal

Metal

In the past wood has been traditionally used on caravans and campers. It's relevantly easy to work with and fix. A main frame is made with timbers being placed in position for doors and windows to be hung. The outside is either covered with aluminum or tin sheets. Gaps are filled with insulation and a moisture barrier is installed. The inside is lined with thin plywood.


PROS AND CONS


+ Lightweight construction.

+ Materials easy to work with.

- Moisture control issues.
- Cold bridge issues between materials.
- Construction can flex.

- Needs outside protection, ideally with bars from tree strikes etc.

Metal

Metal

Metal

Using traditional fabrication techniques in constructing a steel or aluminum frame. This makes for a strong structure, the frames allows for doors and windows to be easily mounted too. Insulation can be placed between the frames. Moisture barriers are added as well as cold bridge gap fillers. The inside lined with plywood. Outside is often skinned in sheet metal. 


PROS AND CONS


+ Very strong construction.

+ Securely mount doors windows and internal cabinets.

- Can become heavy especially if you are limited to a 7.5 ton truck.
- Moisture control issues.
- Cold bridge issues between materials.
- Need a skilled fabricator.

Composite GRP panels

Ex military radio shelter box

Ex military radio shelter box

This construction method uses the latest in glued composite panel technology. Using a GRP outer skin with a foam insulation ranging up to 120mm with a plywood lining on the inside with a GRP smooth high gloss finish. Internal metal reinforcing helps with keeping the unit stiff. Doors and windows are of the glued in GRP type and have no cold bridge gap issues. 


PROS AND CONS


+ Strong construction.
+ Highly insulated.
+ Completely waterproof.
+ No moisture or cold bridge gap issues.
+ Integral steel framing in the floor, side walls and corners.

+ High class gloss finish inside and out.
- Expensive.

Ex military radio shelter box

Ex military radio shelter box

Ex military radio shelter box

These shelter boxes, were well made with insulation and in some cases were designed to withstand bomb blasts and even nuclear fallout. There are many shapes and sizes that lend themselves being made into off grid campers. Work has to been done to remove brackets, shelves and old parts to make way for a livable usable environment.


PROS AND CONS


+ Very strong construction.
+ Secure.
+ Easy to mount to a truck in most cases via twist locks.
+ Cheap to buy.
+ Well insulated.
- Can be on the small side.

- Can be limited in ceiling height inside.

Ex fridge box

Ex shipping container

Ex shipping container

These actually make very good off grid campers. They are well constructed and well insulated with composite GRP panels. Available in a variety of lengths and heights. They can be easily found on ebay for as low as £3,500.


PROS AND CONS


+ Strong construction.

+ Highly insulated.

+ No moisture or cold bridge gap issues.

+ Integral steel framing in the floor, side walls and corners.
+ Cheap to buy.

- Will need to be cut down and any damage repaired.

- Need a skilled fabricator to convert.

Ex shipping container

Ex shipping container

Ex shipping container

20ft containers make a good cheap option for an off grid camper. Some come with windows and an extra door already installed. And if your lucky you might find an insulated fridge version which are rare. 


PROS AND CONS


+ Very strong construction.

+ Secure.

+ Easy to mount to a truck in most cases via twist locks.

+ Cheap to buy.

- Need a skilled fabricator to convert.

- Can be on the small side.
- May suffer from rust and water leaks.

I chose the composite GRP panel construction

The habitation box construction cost - £TBA

This includes all doors and windows fitted.

This excludes the rail on rail sub frame.

Once construction starts images will be added.

frequently asked questions

It was a very close race between buying a ex fridge box and having it converted. But after costing both options out, for not a lot more I could have a brand new composite GRP box. There are quite a few composite manufacturers in the UK. Some who specialize solely in the off grid overland camper market, and produce some amazing examples. After some online research I have found a manufacturer that builds units of the same high specification that's inline with my budget.


No the composite GRP panel manufacturer will be fitting these for me.


I have chosen to use the range of windows, doors and hatches made by Outbound.


It will take one month.


No, I'm having HX60 overhauled and resprayed. The Habitation box with collected and delivered to my workshop where it will out fitted. Then once almost completed, it will craned on to the HX.


move on to the next stage of the build

Move on to Phase 5
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