DIY Awning Construction

DIY Roofwing Awning Construction

The following article is a description of the exclusive CheaperJeeperTV DIY Roofwing awning construction and cost, as seen in this video. The intention and challenges of the design are covered in a previous article and video.

List of Materials and Tools Needed

The following table lists of most of the materials needed for the DIY Roofwing awning construction:

1 – 7’ of 4” ABS Jig Saw
1 – 4” End Cap ABSDrill, Drill Bits
1 – 4” Union piece ABSRatchet Set
1 – 4” Female end½” Wrench
1 – 4” Screw on capFile, Sand paper
1 – ABS Glue
4 – Eye bolts 5/16ths – 2”, washers, lock washer, Nyloc nuts
2 – Piano Hinges
16 – Round Headed Bolts(#10-24) and Nyloc Nuts
1 – 10’ 1/2” galvanized conduit pipe
1 – 12’ x 9’ Tarp 
1 – Spigot
2 – Angles for conduit handle

Steps of Instructions for the DIY Roofwing Awning Construction

Below is a list of steps to follow for the DIY Roofwing Awning Construction.  The steps are available on the CheaperJeeperTV channel in this video.

STEP 1 – Cut the 4” ABS pipe to 7’ in length

STEP 2 – Cut the top opening/hatch

Measure 3” in from each end, then score a line to represent the measured opening to the tube that is approximately 4” x 78”. To cut the opening, drill a ¼” hole at the corners, and insert a jigsaw blade to cut the ABS pipe along the line. When done, use a file to smooth out the edges. 

(CAUTION: If the blade is too fast the blade will get hot and the ABS may partially melt back together as the blade passes, making separation a challenge)

STEP 3 – Instal Internal Pipe Hangers

On both ends of the 4” ABS pipe, drill a 5/16” hole one inch from each corner of the hatch opening you just cut, towards the outer edge of the 4” ABS pipe. In the holes, install a 5/16” x 2” eye bolt. The two eye bolts are to align and form a cradle for the internal pipe on which to wrap the tarp.

STEP 4 – Cut the Internal Pipe Length

If you are using a flat cap at one end of the 4” ABS pipe and a screw on cap on the opposite end of the 4” ABS pipe, the internal conduit pipe should extend into the cavity section in the middle of the screw on cap. The length should be ~ 89”. Use a hacksaw, or pipe cutter to cut the conduit to length.

STEP 5 – Fabricate the Hand Crank Mechanism

Using two angles, and two short pieces of scrap tube(~3”), assemble a handle that can be joined to the inner tube which extends into the screw cap. The screw cap must be removed when wishing to turn the internal bar. A washer and cotter pin(or metal screw) needs to be installed on the inner side of the eye bolt hangers to keep the bar from slipping out of the 4” ABS tube when the screw cap is removed.

STEP 6 – Install the Top Hatch/Cover

Using #10-24 ½” round headed bolts, instal hinges to connect the 4” ABS tube to the top hatch/cover. The round head of the bolts should be in the inside of the tube, connected on the outer side with nyloc nuts.

(CAUTION: The hatch/cover may need to be filed a bit to fit the opening, as the 4” ABS tube may close in on itself slightly due to the material cut out of it.)

Latches, bungee cords or velcro straps may be installed to hold the cover shut.

STEP 7 – Glue on the End Caps

Before gluing on the end caps, if you intend to use the tube to hold water in it, after the awning is deployed at camp, this is the time to install it. Trying to do it after the end cap is installed could be difficult. The install instructions will depend on the spigot you have, but you will need to drill a hole at the bottom edge of the end cap, then ensure the spigot is sealed with washers and/or silicone. Be cognisant of the 4” ABS wall on the inside of the end cap when determining the hole location. Also be careful with where the spigot ends up when the cap is glued onto the 4” ABS pipe.

Before gluing on the end cap pieces, lightly sand all mating surfaces. After you apply the glue to each mating surface, quickly join them with a gentle push and twisting motion to spread the glue between the pieces. Be careful when you do this as the glue sets very quickly.

STEP 8 – Secure the Awning/Tarp to the Internal Pipe

Fold the 12’x9’ tarp on the 12’ edge, and bring the 6’ edge towards the internal pipe. Take three 10”x1” nylon straps and loops each of them through the three bottom grommets. Attach the ends of the looped straps to the internal pile with metal screws.

(CAUTION: DO not put the loops through both grommets along the 6’ edge, or you wontbe able to open the tarp to it’s full extent when fully deployed, as explained in the design article and video.

STEP 9 – Roll Up the Awning

Roll in the awning, and put it on the roof rack on your Jeep. The different ways the awning can be deployed, as discussed in the design article and video will be demonstrated in the next article and video.

To keep the untethered grommets in place when rollin in the awning, use twist ties to hold the edges together. They need only be removed when you wish to extend the tarp over the back of the Jeep.

Itemized Cost of the DIY Roofwing Awning Construction

The costs for many of the items used, in Canadian dollars, is itemized in the table below, and shows a total of ~$131.85(CDN).

1 – 7’ of 4” ABS $51.48
1 – 4” End Cap ABS$5.92
1 – 4” Union piece ABS$3.77
1 – 4” Female end$9.20
1 – 4” Screw on cap$5.18
1 – ABS Glue
4 – Eye bolts 5/16ths – 2”, washers, lock washer, Nyloc nuts~$4.00
2 – Piano Hinges~$16.60
16 – Round Headed Bolts(#10-24) and Nyloc Nuts~3.00
1 – 10’ 1/2” galvanized conduit pipe$8.77
1 – 12’ x 9’ Tarp $7.49
1 – Spigot
2 – Angles for conduit handle$6.47

Conclusion of the DIY Roofwing Awning Construction

The DIY task of making an awning like this is doable, as demonstrated in this article and this corresponding video. The cost of construction is a fraction of commercial quality batwing type awnings.  In the next video and article, we will observe the function of this constructed awning and discuss if it’s a worthwhile venture or not.