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I've always heard them referred to as stress skin panels. Saw them used on an episode of this old house years ago and really liked the idea. Thought it would work well for this project. Weight was a big concern from the beginning. Using these panels eliminates the need for studs and fasteners...

Update Continued gluing wall panels to each other and the deck. I Move it into the shop and night. Tight fit. Hugo checking out the progress.

Progress Report Beautiful weather this weekend. Got a lot done. Used West System epoxy to begin gluing the panels together. Will follow up by covering all seams with fiberglass tape and epoxy.

Exciting afternoon Got some more wall panels made up this morning. Had planned on mounting panels to the floor but instead spent half the day fighting a wild fire. This is a video still from my helmet cam.

I got it at Wurth (formally Charlotte Hardwood Center) in Charlotte NC. Paid $55.00. It was 75f, sunny with a breeze so it took about 10 minutes for it to be ready to bond. Just like any other contact cement, once you bring the pieces together the bond is instant.

Wall Panel Lamination My plan is to build the walls from 1" styrofoam insulation sandwiched between 2 sheets of 1/8" plywood. I was planning on using West System epoxy to bond the styrofoam to the plywood. After a test to see how much epoxy it was going to take it became apparent that it was...

Floor Installed. Have the frame in the shop because it was too cold to work outside. Very cramped but I was able to get the Floor installed on the frame. Its held down with counter sunk carriage bolts and lock nuts.

Very nice.

Frame and floor bottom painted Last Saturday was warm enough to get the frame painted. Also got the floor panels cut, fitted, and bottom painted.

I'm going to build the walls by laminating 1" styrofoam with 1/8" plywood into panels. Cut the panels to size and glue them together with epoxy. Cover the seams with fiberglass tape and epoxy inside and out. Much like building a boat. It should be lite, strong, and waterproof.

The finished size will be 6 feet wide by 12 feet long. I'm using 2X3 and 1X2. Had to temporarily clamp a piece of 1x2 to the frame to hold the tongue in position long enough to tack it.

Tires Mounted - Frame Complete Got the tires mounted and the wheels on. Took it down the road a few miles for a test run. Pulls great.

Wheels A friend from work asked about how the build was going. Told him I had finished the frame and just needed to find some 15”wheels similar to the my jeeps. Well as luck would have it he needed to get rid of 4 OEM jeep wheels and was about to take them to the dump. Took 2 of them to a local...

Construction Begins Began assembling supplies a couple of weeks ago. Picked up 3500# axle tube, spindles, brakes, springs, and fenders from Northern Tools. The steel I ordered from Metals Depot arrived right on time to being working on a beautiful Saturday.

More design images With this design each side of the seat folds out to make half of the bed. This way one of us can sleep while the other reads. We still have enough space to access the bath and kitchen with the bed folded out.

The kids will soon be finished with collage. My wife and I having realized we have more years behind us that ahead of us began talking about travel. My wife has been a stay at home mom and works part time in a tax office during “tax season”. I have served the last 28 years as a Paramedic. We...