The steps mentioned below are what I took to put together the shell of the Darwin.
1) I used the trailer to get the following materials.
QTY(4) – 4 ft x 8 ft x 3/4 inch thick exterior grade plywood
QTY(6) – 1 inch x 2 inch x 8 ft pine board
2) Cut the pieces to length. If you don’t know how to use a saw or are not comfortable using a saw, find someone that is. Many of the home improvement stores will also cut boards to length for a small fee.
QTY(2) – 41″ x 63.625″ (plywood) – used for fold down bed doors
QTY(2) – 30″ x 45.75″ (plywood) – used for the two ends of the camper. One will have a door cutout on it.
QTY(4) – 1.25″ x 64″ (plywood) – used for the roof sub-assembly
QTY(2) – 4″ x 64″ (plywood) – used for the floor sub-assembly
QTY(1) – 30″ x 64″ (plywood) – used for the floor sub-assembly
QTY(1) – 27-5/8 x 64″ (plywood) – used for the roof sub-assembly
3) After all the boards have been cut to length, utilize the small 1″ long 80/20 aluminum extrusion to drill the holes in the front and rear panels of the Darwin body. These holes will be used to bolt the Darwin together.
The following items will need to be ordered from 80/20 (extruded aluminum manufacturer):
QTY(1) – 30-3022 at 1 inch length – used for a guide to sand radius of ends of camper and also for center punching hole for mounting the 64 inch 30-3022.
QTY(4) – 30-3022 at 64 inches in length with tapped hole on each end – used for holding ends of camber together.
QTY(20) – 13096 t-nuts
4) Assemble the bottom of the Darwin body by attaching the two thin strips to the large board.
5) Drill holes for mounting the extrusion to the edges of the floor. This will require you to use a larger drill bit to countersink the holes for fastener clearance.
6) Insert the 1/4-20 x 1″ fasteners through the drilled holes and thread on the t-nuts. This will allow you to slide the extrusion over the t-nuts and then tighten down the nuts to fasten the extrusion to the floor assembly. The final assembly will look like –
7) Take the same steps to assembly the roof portion. The main difference is that the roof portion will be flush with the 30-3022 extrusion.
8) If you have not done so, cut the hole for the door.
Go back to step 5 or go to step 7 of the DIY camper plan instructions.
Circular saw, socket set, drill bit set, drill