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Here's the video on the subframe design. Goes into more detail and a lot more visuals than I could provide here:

Thought I'd share a link to our YouTube & Instagram if anyone is interested in following along on the build there. Still planning on keeping the forum up to date, but will be using instagram for more photos and everyday building/progress, along with YouTube for long form video. Speaking of...

Final Mounting of the Subframe + Exo: After countless setbacks with mounting, we finally got it done. We had endless issues with the factory Ford body mounts including incorrect part numbers from Ford, inconsistent manufacturing flaws, rust, and user install error. As I’ve already gone over...

Yep, exactly. I based my spacing on the regular body vans. Though I don't use the Ford lateral spacers, I used a polyurethane body mount puck to get the extra little bit of height. This also acts as a cushion if any frame slap occurs with the spring mounted design. As for the body mount...

In the photos you see, the subframe was mounted using 3d printed body mounts that I used during construction just to make things easier. The subframe ended up nearly exactly even with the cab floor with the actual mounts, so yes the habitat floor is the thickness of the floor(1.625in) +...

Seems like the 450 DRW 158 is a good fit for your use case! Only thing I will say, is if you are comparing the amount of space to your RB, my van has the exact same length (and overall width) as an RB e350 but I've been inside both and its amazing how much larger the inside is with the straight...

I had no luck with any dealers, none of them had any or could order one anytime soon. It was also very difficult to search for them and specific one without a box, not to mention most of them were larger and duallys. I think you may have better luck trying to find the 158 Dually you're looking...

Here is how the left crated from Lemker and the whole stack of panels sitting in my backyard before we got to using them. (ignore the dirty panel that is a scrap I got from them!)

Thanks! I've gotten a lot of questions about the panels I'm using so just made a dedicated post to outline my experience with Lemker and help others with finding a source. https://forum.expeditionportal.com/threads/composite-panel-source-for-diy-expedition-campers-lemker-panels.244931/

If you're interested in my build here's a link to my build thread. I haven't gotten to the panel installation part but will soon! https://forum.expeditionportal.com/threads/e350-cutaway-4x4-w-diy-pop-top-composite-camper-box-build-thread.241475/page-4#post-3166023

Cutting/Working with the Panels: Having them cut it is really the way to go if you are able to plan out your exact dimensions ahead of time. Unfortunately I just had too many constraints and undecided joints so I oversized the panels and planned to cut them myself. The good news is that their...

Finding a good source for composite foam core panels in the US took some time, so I thought I would share who I ended up going with and my experience now that I’ve used the panels. I initially planned to build my own for the longest time, but decided against it because: Everyone on the forum...

Painting! I’m not going to go too in-depth into the painting because we are far from experts on this, and honestly, I hated the entire painting process. We used SPI Epoxy on the entirety of the frame and as a primer for a single stage white topcoat on anything that would see UV exposure. You...

Exo Skeleton/Rear Carrier Finished! Finishing up the exo was pretty simple, it just involved welding all of the corners together. This created a good amount of distortion and isn’t the prettiest, so I designed and ordered some corner caps to add some extra strength and give a finished look...

Completing the Subframe There were a lot of unforeseen details that went into finishing the subframe, the first of which was framing out the wheel wells. Unfortunately, I originally sized the wheels wells based on Ford’s guidance, which proved to be pretty incorrect (way too big) considering...

Been busy working on the camper and MIA on the build thread for a while. Going to post updates over the next week or so on everything we've gotten done since!

Thanks! I'll put in an order today. I hope it's still in stock, it was when I checked a week or so ago! Just to confirm, you're using 205 on the FRP side too? do you bother scuffing the panels side beforehand?

You have me sold on 225 (that I will be order through you once I get this all figured out!) Can you confirm the best prep-steps/activator/primer for 225 for bonding aluminum/fiberglass? Thanks!

I actually will be using 3m VHB as my spacer material to make the adhesive happy. I'm sure it could be used exclusively to make a box but I prefer the bonding strength of traditional PU adhesive! VHB sounds great for your application.

I am planning to use korapop 225 for the assembly of my box (aluminum Exo to FRP Gelcoat panels). This part is at least decided I'm looking for more information on the best prep advice including activator and primer. At this point my plan is to: Clean Sand to 80 Grit Vacuum/Clean again with...