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  1. J

    Flatbed and composite panel build on Dodge 2500

    Thank you very much! Appreciated. There is only 3" under the shower pan and 6" under the toilet which will have an access door from the inside. Enough room for a little bit of storage and access for plumbing for the Whale Gulley IC waste water pump, check it out here...
  2. J

    Flatbed and composite panel build on Dodge 2500

    Side view: perfect thing to store in a tapered area, should drain good!
  3. J

    Flatbed and composite panel build on Dodge 2500

    Grey tank So, if you have a 35 gallon fresh water tank, shouldn't you have a 35 gallon grey water tank? I am curious why most manufacturers have a substantially larger fresh than grey? Toilet is a cassette so it takes care of it's own volumes and they pretty much line up for flush water/black...
  4. J

    Flatbed and composite panel build on Dodge 2500

    Got the cassette toilet in, and all of the hardware for the bathroom, cut formed and welded up a shower pan out of .125 5052 aluminum, stiffeners under the toilet and under the pan to distribute load evenly. This is what happens when you can't buy a shower pan that looks like it would last a...
  5. J

    Flatbed and composite panel build on Dodge 2500

    Bernie, here is a size chart from Dometic, in North America the S4 windows are stocked: Jason77, the extrusions are not available by themselves, we use them for builds in house and have 8 week windows between orders and we don't want to end up stalling the shop. I can however build you a bare...
  6. J

    Flatbed and composite panel build on Dodge 2500

    Thanks for the grammar lesson, didn't quite look right! I can supply Seitz windows, are you able to adjust the window openings on your camper to accommodate the windows? Thanks, Mark.
  7. J

    Flatbed and composite panel build on Dodge 2500

    Where's your sense of fashion! Ya gotta see it to believe it, was really cool stuff. I looked into it a little too, the fabric is coming out of the USA and no issues shipping into Canada or Mexico, HOWEVER last time I crossed the border I got a bottle of California red wine seized at the border...
  8. J

    Flatbed and composite panel build on Dodge 2500

    Processed hemp? Never thought of that, I will have to check it out. The fabric blows a lot of other fabrics away, and has a good "feel" to it.
  9. J

    Flatbed and composite panel build on Dodge 2500

    Yeah it's a little on the bright side. All cabinets are going to be darker wood, and Crane Composites makes a really nice class C fire rated interior composite wall panel that comes in really nice colour and texture combinations which will really richen the interior. Is richen a word?? Found...
  10. J

    Flatbed and composite panel build on Dodge 2500

    A couple of vertical walls up, started working on the cabinet layout in the real world compared to the CAD layout and it looks good. Going to do a full CAD model of the cabinetry and CNC router cut the whole deal, at least that's the goal. There might be a few saw cut pieces on this one!
  11. J

    Flatbed and composite panel build on Dodge 2500

    Hey Don, you are close enough to come have a look under construction, might give you some good ideas.
  12. J

    Flatbed and composite panel build on Dodge 2500

    Minor progress, all the rest of the panels are cut, got the rear lower on, all vertical walls are going on next, and I will install all of the tall cabinets and the wet bath walls, then the roof will go on last. Much easier than trying to put big cabinets through a small door, much more...
  13. J

    Laminated double pane window panel blanks.

    Use urethane glass sealant/adhesive. Try to find one that is UV resistant, otherwise you will have to prime the edge of the glass to keep UV from hitting the adhesive. This is why windshields are painted black around the outside edge.
  14. J

    Flatbed and composite panel build on Dodge 2500

    I love my cave! Interior dimensions are (interior) 81" Wide, 8'6" Floor length plus rear is kicked out another 18" for a total front to back wall length of 10'6", back wall to the nose of the camper is just over 16', room for a queen bed up top. Panels are generally made close to size, all...
  15. J

    Flatbed and composite panel build on Dodge 2500

    Got some walls up, the box inside is the fridge and its about 3" larger than the actual cabinet for it will be, the flat floor plan really makes for a lot of very useable space for gear and living. The layout basically gives 2 semi isolated living spaces, the master bed in the overhead will be...
  16. J

    Flatbed and composite panel build on Dodge 2500

    The riveted extrusions use the rivets for a mechanical structural connection between the extrusion components only, there is a bead of Sika laid in between but when the 2 aluminum components are riveted together in a zero clearance fashion, the Sika becomes a sealant more so than an adhesive...
  17. J

    Flatbed and composite panel build on Dodge 2500

    Got the extrusions coated and assembled the floor. LOTS of 252! Lowers were riveted to the upper extrusions with 1/4 coated Uni Bolts, 4000 lb shear, 2400 lb pull out strength. Shot of the lower rear corner, 3/16 5052 aluminum wraps 4" under the bottom, good protection, will help with...
  18. J

    Flatbed and composite panel build on Dodge 2500

    They are included with your camper or expedition truck from……...
  19. J

    Flatbed and composite panel build on Dodge 2500

    The floor is 3" thick, and all my extrusions are set up for 1 1/2" panels but I did design them to be easily manipulated, so I trimmed off 1 edge and formed a 90 degree flange from 3/16 5052 aluminum. The flange gets riveted to the extrusion and it will accommodate the 3" floor and the 1.5" wall...
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