Cruisemaster in AU has been doing this for decades. Mario and the gang at Adventure Trailer tried it and it was expensive and Im guessing they didnt sell many. People talk about wanting lots of things but dont necessarily want to pay the cost for them. Cruisemaster's XT cost $4000 to get to...
Ditto with what Sg1 & DzlToy said. If you want to go overboard put some angle on the inside as well. You can use SS for an accent. But really these boxes have been being built for 30 years and adhesives and cores have only gotten better since then. If it weren't working folks wouldn't be...
One thing to remember is some adhesives and or foams used in building can only tolerate so much heat. One of the reasons most sandwich builders us lighter colors. In northern CA dark grey vs white can be 30+ deg F difference. This is the surface of course.
Take a look at ZoneRV in AU. They have used ACP and tubing in their vans for several years, it will give you an idea of how it looks finished. You can look at the specs of Dibond and see strengths/weight vs plywood.
Take a look at Aluminum Composite Panels. Can be routed and easily bent. Use thin wall aluminum with connectors, no welding, and bond the ACP to the tubing. Several European and Australian builders have been doing this for years.
Depends on price point. You have Linak as probably the best, and most expensive, then you have all the off shore knock offs. Firgelli is one of the larger names of knock off but they are remarkable similar to the ebay/amazon versions, except you have a resource for questions or returns. If...
Put 40K on a 02 a few years back, would get another in a heartbeat! Great trucks really very basic engines, only downside is parts are MB premium. Not really a deal breaker just to be aware. If you're in Northern CA you have Collie's in Marin for a real G certified mechanic.
Just FYI on Dibond panels. There are several manufacturers in the US and at least one from the UK available stateside. Dibond is sort of the Kleenex tissues of aluminum composite panels, just look around for prices. In Northern CA I can get the UK version a fair bit cheaper. Also, there are...
If you know someone with a large belt sander (25 "+) you can run them through that. Removes the embossing, roughs them up and even out any variance. You only loose than an 1/8" between doing both sides.
To buy the precision planed panels either Dow or OC, they generally want a literal truckload. Now if you can find someone using those volumes and piggyback with them you might be in luck.
They have been around for 20 years and are one of the largest if not the largest supplier of panels. Im guessing there have been more than a few boxes used off road. They are very helpful and will answer questions via email or by phone.
Starboard is great stand alone material, but too dense for laminating. Cant recall if they have thinner materials, but I think .5" is the thinnest and its very heavy. FRP/GRP or wood is the most practical, another option that isnt discussed much is aluminum. Aluminum composite panels 2 mm...
I think the general consensus for the off shore plasma is they are all similar and it really comes down to support. If you get a dud, which happens, how hard is it to get replaced. And finally consumables; easy or hard to find/cheap or expensive for purchase.
That being said I've had a Lotus...
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