1 Bored Clerk's DIY Camper

[1 Bored Clerk]

Well, I just ordered my wall/roof panels from Carbon Core. Here's what I got:

20mm honeycomb Core
18oz composite skins
Sanded both sides
4'x10'

Should take about 4 weeks to build and some unknown at this point amount of time to ship. (1-2 weeks?)

Really pumped to have that in process!


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[1 Bored Clerk]

Did a test layup today. Gave me a chance to try the process and get a feel for everything including how much resin I can get away with.

Three layers at the top and two layers on the bottom. It'll be good to see exactly how thick built up areas will be for planning my camper mounts and drawers.


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[IdaSHO]

You need to work that glass more to get it 100% saturated with epoxy.

It takes some effort, especially if you are working in colder temps as the epoxy is thicker.

Once you get it fully saturated, it will be completely clear.

And clear is what you want.

Also, what weight cloth are you working with?

 

[1 Bored Clerk]

The 6" wide cloth I'm working with now is 6oz. I made a few mistakes: not getting the cloth wet out enough and also not prepping the wood well enough. The cloth on that sample seems to be held together really well but I was able to pull it off the plywood easily. My guess is that the glass soaked up all of the resin before it could soak into the wood. I'm thinking I'll coat the plywood then let it get to the green stage then add another coat and start with the glass. I seem to remember reading that's the right way to do that...but forgot at the time. Please let me know if I'm wrong!

Also, I'm sure I'll make all kinds of mistakes on the camper as I go. All part of the process I guess. I'd like to avoid as many as possible so thanks for your input! I really appreciate it.


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[IdaSHO]

You'll get there :ylsmoke:

Are you glassing the entire thing, or just the joints?



With good ply, one seal coat is plenty to prep the surface.

With a 6oz cloth, you will be better off applying a fresh layer of epoxy to the ply before applying the cloth.
Apply cloth, then more epoxy for the wet-out. It will still require some effort to get it to wet-out completely.
But dont stop working it until it is 100% saturated and clear. Then concentrate on flattening and smoothing any lifted sections of glass.

With the 6oz cloth you might be better served with nothing more than a 4" metal putty knife for the wet-out.
It will allow you to apply some good pressure to the surface to help saturate the cloth.

 

[1 Bored Clerk]

Thanks!

I'm just going to tape the major seams on the inside then probably glass the whole exterior. I could just glass the seams and the higher stress areas around the compete mounts too??


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[IdaSHO]

With the good ply you are using, you really don't need to glass the entire thing.

While glassing just the joints works, I've found it to be a bear to blend/hide the joints well, especially when using a heavier cloth like 6oz



If you have intentions of glassing the entire thing, then also consider this approach... If I can explain it properly.

Use a lighter 4oz cloth to glass the entire thing, wrapping corners as you hit each surface.


Each surface as in, glass the front, and around the corners an inch or two.
Then when you glass the opposing side wall or roof, wrap the corner again.


This gives you 4oz cloth throughout, with a double layer of cloth on the major corners.

The 4oz is plenty thick, easier to work, and uses less epoxy to apply.

 

[1 Bored Clerk]

Yeah, that's very clear to me! I'd rather not add unnecessary weight and time and hassle if at all possible. I know this camper base is probably built too heavy but whatever...I'm learning as I go! The walls and roof should be pretty light (composite honeycomb Core panels). I can practice my 4oz cloth work on the base (hidden in the truck bed) then apply it to the walls and roof.


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[CoyoteThistle]

I've found that these little squeegees are great for working the epoxy in/out of the cloth (stiffer white ones) and work well for fairing as well (slightly softer yellow ones).

Less than a buck each a lot of times. Most fiberglass supply places will carry them. You can get similar ones pretty much wherever they sell Bondo too.

I'll second the idea of 4oz cloth - will also wrap corners easier and be less work to sand/fair.

Nice progress - look forward to the upper structure coming together!

 

[1 Bored Clerk]

Thanks! Yeah, I'm excited to get this thing done. It'll be a few more months but I'm making slow but steady progress


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[1 Bored Clerk]

Been getting some work done on the camper.

Laid some fiberglass. Did a much better job than my sample I think...thanks to all the good help here!

Picked up my roll of 4oz fabric.

Flipped the camper over and prepped it for epoxy and glass tomorrow.

Picked these up today! These will be the mounts for my drawer bulb seals. Maybe a little overdone but they'll at least look cool...when the drawers are open. Haha. I'll get them anodized before final install so they don't corrode.




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[1 Bored Clerk]

Glassin'

One big sheet of glass fabric. It's was a lot for a noob like me to wrestle into place and smooth out. Took some time too! I think it's pretty good. I took some extra time after these shots to work on the corners. Back at it tomorrow!


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[1 Bored Clerk]

Did this whole multi step side in one piece of glass. It was a bit frustrating and took a long time to get dialed but I think it's good. I may do the other side in 2-3 pieces to make my life easier.


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[1 Bored Clerk]

Finished all the big glassing on the bottom of the camper. It looks good from across the street. Haha


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[b dkw1]

Looks good from My house LOL........

You are a brave man, fiberglassing is something I have zero desire to ever do again.