4500 Camper/Jeep Hauler Build

[gprguy]

Man that looks awesome. Excellent work man, excellent work.

Thank you, and thanks for the Victron gear!

 

[jsalbre]

Thank you, and thanks for the Victron gear!

Happy to have been able to help!

 

[gprguy]

Nothing nearly as exciting today - finished off the DRVM rear camera to replace the wireless camera that came with the Lance.



Edit: Turns out the aftermarket cable is a bad idea, see this post for details:

Post in thread '4500 Camper/Jeep Hauler Build'

Jul 6, 2025

The cable is a RP-TNC to Fakra connector, and then a fakra extension up to the camera. This uses the stock little adapter to the weird truck side connector. This let me build a cable to length instead of using the stock 50' or whatever it is cable. I 3D printed the cable clips out of ASA and a grommet out of TPU to go down through the camper bumper. The "docking station" for the cable when it's not in use is mounted underneath the camper.

Other than that, took the camper back off the truck so I can start on the deck trim tomorrow.

Update to an old post - turns out the aftermarket...

• gprguy

• 

The cable is a RP-TNC to Fakra connector, and then a fakra extension up to the camera. This uses the stock little adapter to the weird truck side connector. This let me build a cable to length instead of using the stock 50' or whatever it is cable.

I 3D printed the cable clips out of ASA and a grommet out of TPU to go down through the camper bumper. The "docking station" for the cable when it's not in use is mounted underneath the camper.

Other than that, took the camper back off the truck so I can start on the deck trim tomorrow.

 

[Eatonpcat]

Man that looks awesome. Excellent work man, excellent work.

X2

 

[G Mcpherson]

Great Build. I've enjoyed following the Process. I'll keep an eye out for you on the Road. One of a Kind.

 

[gprguy]

I've been working on the bed edge trim the last few days. My plan is to get the main parts done now, and do the corner caps after our first trip. The corners will look a little ragged till then, but I just don't have the time I don't think.

So anyway, the edges need various bits trimmed out for the fuel fillers and the wheel wells. We're making the trim out of 2x4" 1/8" thick aluminum angle, so we can carefully use a trim router with a carbide bit similar to doing formica countertops.

First, notch the top edge for the fuel fillers using a flush cut bit with the bearing at the bottom.





Next we need to notch around the plastic fuel fill necks. I traced the bottom profile with some paper, scanned that into Fusion 360, and traced it to make a guide that I 3D printed.



Moved over to the fab table, and switching to the router bit with the bearing at the top, I can cut around the pattern.



Forgot to take an after picture, but they fit nicely.

Here's the other pieces, all fit up around the bed.



Last, I need to cut some wheel arches. Again, I made a 3D printed template. This time in two pieces since it's so big, joined with a dovetail.



Over on the table, part way through the cut.



All done.



Pretty happy with the results.



This is with the suspension almost dropped, I dropped it the last 1/4" afterwards and there's still plenty of clearance.

That's where I am at, tomorrow I drill a bunch of holes and start attaching the trim.

 

[gprguy]

Made a big push the last two days to finish the trim.





@Units how's your OCD feeling now?

Other than knocking together a temporary bracket for the DRVM bumper plug tomorrow, that's it for "phase 1" shall we say. I need to clean up the excess sikaflex around the trim tomorrow, reinstall the spares, fill the fuel tanks and get it weighed. Then it will be getting everything ready for a quick overnight shakedown trip this weekend.

The build definitely isn't over though, still lots to do after we get some vacation in.

 

[jsalbre]

That looks so good. Most professional builders aren’t producing beds that clean.

 

[Great White North Eh]

Ya it should be parked on the street at SEMA and see how many necks twist of people wondering why it isn’t inside.

 

[gprguy]

Thanks. I can see the little cosmetic flaws but I'm pretty happy with it. It looks pretty good from 5 feet. Will get some weight numbers posted later.

 

[Units]

Made a big push the last two days to finish the trim.

View attachment 81598

View attachment 81599

@Units how's your OCD feeling now?

Other than knocking together a temporary bracket for the DRVM bumper plug tomorrow, that's it for "phase 1" shall we say. I need to clean up the excess sikaflex around the trim tomorrow, reinstall the spares, fill the fuel tanks and get it weighed. Then it will be getting everything ready for a quick overnight shakedown trip this weekend.

The build definitely isn't over though, still lots to do after we get some vacation in.

Well, I could mention the……………..

Just kidding . Great work
As @jsalbre mentioned. Want it done right, you gotta do it yourself.

 

[gprguy]

In case you were curious (I know I was), a spare 4500/5500 tire on a steel wheel weighs 119 lbs.



So I am toting around 240 lbs of spare tires.





Worth it, IMHO.

 

[jsalbre]

Have you thought about putting a tire cover over the spares to protect them from the sun?

 

[Metternacht]

Have you thought about putting a tire cover over the spares to protect them from the sun?

Something like this --> or or

 

[gprguy]

Have you thought about putting a tire cover over the spares to protect them from the sun?

I have but it's really low priority. The truck lives inside when not in use, and when the camper is on it the tires are pretty well shaded. If I were parked down in AZ for a month then I'd figure out something for sure.

 

[gprguy]

Back from the scales. I guessed 300 lbs low - I was hoping the bed would be around 700 lbs but it's just under 1,000. Total weight after adding the bed, bike rack, 240 lbs of spare tires and filling the tanks (400 lbs more) - 11,860. It'll work.

A couple of photos before it got dirty(dirtier) on the road.





Tomorrow the camper gets loaded and we're going to take a test trip this weekend.

 

[gprguy]

Back from our overnight test trip. Couldn't have gone better - zero issues. The truck drives fantastic with the camper on it. Much quieter and smoother than our 2018 3500 dually. The truck shifts so much better as well - my '18 had the Aisin also but they clearly have put in some time improving the shift algorithms. I also noticed the camper moves around less than on the 3500, especially longitudinally - you could see the frame flex slightly on the 3500 after hitting big bumps, and with the chassis cab the camper barely moves at all. Some of that could have been the sheetmetal bed as well, but point is the new truck is a lot more solid. The Kelderman rides like a dream with the camper on it too - really impressed.

Also, somehow, so far, we are getting about 1 mpg more than with the 3500. Accidental aerodynamics perhaps with the camper pushed back further and the flare out of the backpack box? We'll see if that holds true. Glad I ended up with the 4.10's, if we had gotten the 5500 we originally ordered it would have had 4.44's.





Two weeks to get ready for the truck camper rally in AZ, and plenty of odds and ends to finish up.

 

[Brutal_HO]

Kickass

 

[Bigboom338]

Theae 45/5500 chassis cabs are the bomb for truck campers. Did you happen to run across the scale fully loaded?

 

[jsalbre]

Glad to see you finally get to enjoy all that hard work! Nice job, it looks great!