1. Cabover Camper Priyanka Chand Tyler Croissant Nik Roetemeyer
David Stasiuk
Robert Sutton
Jonathan Wacker

2. Project Background Customer : Zdenek Zmur Project Scope:
Design a 2 person external sleeping compartment for a 2011 Jetta Wagon
Vehicle attachment points: Roof Rails and Aftermarket Hitch Receiver
Allowable weight (Dynamic):
Roof Rails : 150 lbs
Hitch Receiver : 200 lbs (Tongue Weight)
Jetta Suspension : 300 lbs
Ridged Solid Walls
3 Seasons Design (Fall, Winter, Spring)
Reduce mpg impact
Goal: Prototype built by June

3. Jig Fitting
Expedition Tents
James Baroud Offroad Tents

4. Size & Shape Two Person Backpacking Tent as Reference.
Floor Dimension : 50” x 84” Max Height : 39”
Triangular Design vs Box Clamshell Design: Weight and manufacturing cost!!
Current Design 48” x 80” Floor With 36” head room
Excess overhang of roof width will increase drag
As designs progress dimensions subjected to change as to optimize weight to space.

5. Design Schedule Project Break Down : 2 Stage
Vehicle Attachment & Bed Area
Design, Fabricated, Tested
Caveat: Fitting around Zdenek Zmur Personal Schdule
Shell Design & Final Testing
Design started with more focus after 1st Stage completion
Finished Assembly
Cost Analysis
Determine if viable consumer product

6. Bed Frame & Ladder Design

7. Rail Clamp Design & Cross Bar Design
Thule 1054 Roof Bar & Clamps
Cost Effective
Saves on Design Time
Cross Bar Design
Provide Significant Rigidity for Bed Area
Industrial Structural Steel
Strength To Weight
Costs effectiveness
Material Selection and Manufacturing
Steel vs Aluminum
Weld vs Fasteners

8. Fitting to The Jetta Unable to Source 3D model of Jetta
Manually Fit to define profile

10. Analysis Deflection and Stress Analysis of Frame and Ladder Structure
Max Stress: 11.5 KSI
Max Deflection: 0.17”

11. Analysis
Weight Analysis : lbs

12. Canopy Design

13. Materials Laying surface ACP (Aluminum Composite Panel)
48” x 96” x 3mm Weight: 26 lbs
Top & Side
Coroplast
4mm Thick

14. Design Progression One off Design Fabricate / Fit Frame and Ladder
Revise Canopy
Explore Coroplast Thickness
More precise/reproducible cut profiles
Fit and Finish
Production Run
Make Frame shape generic to fit wide variety of vehicles
Generalize ladder for range of vehicle