2022 Ford F550 - DIY - Adventure Expedition Vehicle Build Thread

[Vance Vanz]

Carbon Fiber Enclosure Panels - Grey Water Tank - Layout & Mold Making

The fairing material needed a few days to cure before sanding, so I jumped onto the enclosure panels (x three) for the grey water tank. I though about not doing these (to save some time on the build), or doing them after I/we return from the trip. But ............, the reality is, if I don't do them now, they will probably never get done. It is one of those things I would regret not doing now, so I had my answer. They are needed to make sure the camper is four season-insulating the grey water tank/drain lines.

Layout for the molds



These pesky little pieces are going to be a PITA


Mold making


Back enclosure panel


Angled bottom enclosure panel (One of two bottom panels)

 

[Vance Vanz]

Carbon Fiber Enclosure Panels - Grey Water Tank - Layups

Staged and prepped for three layups


First layup on a pump


Second layup


Third layup finally on a pump


Everything on a pump for the night


That was a long day

 

[Vance Vanz]

Carbon Fiber Enclosure Panels - Grey Water Tank - Demolding & Dry Fit

Demolding


Rigging camper in order to dry fit panels.


Dry fitting panels/Back panel. (Sorry for the wonky pictures. There isn't much room to take decent pictures with the stand in the way/acting as a safety net.)


Bottom angled panel


Bottom panel


All three panels: trimmed, shaped and ready for bodywork & coating


Fingers crossed, these are the last composite parts on the build that will need to be fabricated. I would love to say I have some feeling of accomplishment around this milestone, but all I can think about is how much bodywork I still have to complete !

 

[Vance Vanz]

Pass Through Flanges - Final Paint

These needed to get done before the truck/camper go off to paint/coating, but I think I'm honestly just procrastinating from getting back to the bodywork on the camper (the first major sand).


There is a touch of texture on the visible inside portions of the cab-side pass through flange that should match the texture on some of/many of the factory painted items in the crew cab area. The details!

 

[Vance Vanz]

Camper Fairing/Bodywork - Bottom Exterior - Continued

Now that I am in a single room shop, I have to do something to keep the sanding dust contained. The last thing I want is epoxy based fairing material dust all over everything in the shop, especially where I eat lunch and dinner. This stuff is bad enough if it gets anywhere on my skin and I can't even imagine what it would be like to eat some of it.

Remember when you used to make forts out of blankets as a kid, well those skills are finally coming in handy as an adult 😄



Well, I can't procrastinate any longer; it's time to re-enter the dark side. Back to sanding. This will be my plastic fortress/home for the next few weeks.

One tough long week of sanding, and applying the second coat on everything, has passed.


Lucky for me, it's time for my sweet heart and I to head off to Burning Man for a bit. Two WACKADOOS headed out to have some fun with thousands of other domestic and international Wackadoos. It's been awhile since I have gone, and it will be my partners first time going, so I'm excited to experience it with her. I definitely need a break from composite and bodywork, although I am so close to being done with it all!!!!

The next time I post to the thread, the composite and bodywork should be a thing of the past.

 

[rruff]

I gotta know... about how many hours do you figure you'll have in this before it's finished?

 

[Vance Vanz]

I gotta know... about how many hours do you figure you'll have in this before it's finished?

Sorry for the belated reply rruff. I completely unplugged for Burning Man.

To complete the whole project , I'm guessing, hoping 🤞, 2 years 6 months will do it (max 2 years 8 months). This is actual working time at 12 hours a day, 7 days a week. Somebody can do the math at 52 weeks a year.

March 1st, 2025 will be three calendar years I have been on the project full-time and a 4 to 6 month deduct for vacations, time off, sick days, ect. will be as close as I can get to a total hour figure. Realistically, it is probably closer to the 2 year 8 month mark (at these figures) considering the amount of days I have worked over 12 hours a day.

I'm also probably not calculating the total hour figure because the reality of doing so would: create a hard lump in my throat , I would not be able to swallow 🙁, then the tears would start to flow 😭 and the question of (What in the F have I been doing with my life? 😩) would eventually follow. 🤪😆, but seriously!!!!

Off to sanding.

 

[rruff]

About 11,000 hrs... yikes! Over 5 years of full time work...

Hope you had a great time at Burning Man!

 

[Rondo]

Would love to know where you're at with this project. It was a great read. Also, how are you storing bikes in that locker?

 

[ITTOG]

Would love to know where you're at with this project. It was a great read. Also, how are you storing bikes in that locker?

Me too.

 

[180out]

well, its been 4 months or another 1500 work hours. maybe he is out camping in it! i hope so.

 

[Vance Vanz]

Would love to know where you're at with this project. It was a great read. Also, how are you storing bikes in that locker?

Thanks Rondo!

I'm still cranking away and need to do a massive build thread catch up.

Currently I am up to my neck on a build project that has a deadline and I'm not sure I'm going to make it. When the dust settles, in a week or so, I'll answer your specific question and start getting the thread caught up.

Chat soon!

 

[gator70]

Lots of work - a labor of love

 

[Vance Vanz]

Would love to know where you're at with this project. It was a great read. Also, how are you storing bikes in that locker?

Weeks just roll into months on projects like this!

I'm sorry that I have not respond sooner Rondo.

To answer your question related to the MTB storage in the back gear locker "The fun closet".

The MTB/bike will be oriented vertically, standing straight up on its back tire, with the front tire removed. The handle bar will be spun 90 degrees, so it will be vertically inline with the frame. The back tire will sit on and be strapped to a MTB tire tray, which will be mounted to a recessed track in the floor. A clamp style quick-release fork mount will be used on the front fork. The fork mount will be secured to another piece of track, which will be mounted vertically on the side wall of the locker.

Two of these setups will be installed, side by side, so two MTB's can be stored in the locker. The front tires will also be stored in separate tire-bags and these will be strapped/secured to additional track that will be mounted to the walls of the locker.

I'll take some pics when I eventually get to that part of the project.

Again, apologies for taking a bit to get back to you.

 

[rruff]

If I'm visualizing your description correctly, you'll need to get the angle exact on the fork mount, and it will be bike specific. Maybe if there was pivot between the mount and track? Extra lateral support would be needed too, because the fork mount won't provide that.