Building new lift panels. Why not 1/8" aluminum ??
- Thread starter Aaronn
- Start date
cchoc
Wilderness Photographer
I'd worry about bending.
ExpoMike
Well-known member
The biggest thing I could think that would be a problem is the thermo conductivity of aluminum, especially the one at the bed end. Since these are right against the canvas, cold and hot temps could cause the aluminum to become very cold or hot and could create condensation due to the thermal dynamics. Strength wise, I don't see a problem, it's the thermo dynamics that would keep me from doing it. The plywood and new composite ones don't conduct heat/cold like aluminum would.
This more than anything else with Alum. There are all types of alum, some would be too soft but others would be fine. The good stuff is also expensive.
If I had to do a panel rebuild I might try something like this.
Buckshot62
Observer
Why not 1/8" aluminum ?
I have wondered this for years. ( I have an 86 Fleet and an 83 Grandby... both have small leaks that ruin boards over time ) The leaks are not bad and I don't plan on spending a grand or so to fix it. Yesterday at Menard's I found HDPE (? )in 4'x8' sheets in 1/8" or 1/4". 1/4" was 55.00 a sheet. Considering using this instead of plywood this time. How much is a 4x8 sheet of aluminum ? Just went out and measured my Grandby (factory boards ) 5/32" or about .150 thou. After all my rambling I don't have an answer for you but this let's you know you are not alone in trying to find another alternative.Let us know how it turns out for you .
I have wondered this for years. ( I have an 86 Fleet and an 83 Grandby... both have small leaks that ruin boards over time ) The leaks are not bad and I don't plan on spending a grand or so to fix it. Yesterday at Menard's I found HDPE (? )in 4'x8' sheets in 1/8" or 1/4". 1/4" was 55.00 a sheet. Considering using this instead of plywood this time. How much is a 4x8 sheet of aluminum ? Just went out and measured my Grandby (factory boards ) 5/32" or about .150 thou. After all my rambling I don't have an answer for you but this let's you know you are not alone in trying to find another alternative.Let us know how it turns out for you .
You are not alone. I have seen two done that way, the one Bill Harr posted above and one on the internet in a for sale add. The for sale one was done in diamond plate and from the add photos appeared to have been well done. I too have one; the rear lift panel on my Grandby is on its way out. I'm considering going either an aluminum or maybe polypropylene route. The diamond plate one was much narrower than my current wood ones. That for me would be a plus as the canvas tends to rub on the edges of the boards in the down position if I'm not careful in how I pop down.
ExpoMike
Well-known member
You could always apply some fiberglass cloth and resin to make them waterproof and add some strength to them. Do that and likley would never have to build another set as they would not delaminate, warp or rot due to any water leaks.
Your answer lies in composite panel construction.
They are quite rigid and light for their thickness, certainly compared to 1/8" thick aluminum sheet. I have some panels that are 2" thick, weigh one pound per square foot and have an R value of about 30 with a special heat reflective coating sprayed onto one side of the panel.
This may not be required for a small truck camper, but is definitely superior to any single material such as plywood or aluminum sheet.
The skins can be made from a wood veener, sheet steel or aluminum, fiberglass, phenolic, ABS or any number of other materials. The cores are typically honeycomb based (Plas-core or Nida Core type products) or an EPS/XPS foam based. Each has its advantages and disadvantages.
They are quite rigid and light for their thickness, certainly compared to 1/8" thick aluminum sheet. I have some panels that are 2" thick, weigh one pound per square foot and have an R value of about 30 with a special heat reflective coating sprayed onto one side of the panel.
This may not be required for a small truck camper, but is definitely superior to any single material such as plywood or aluminum sheet.
The skins can be made from a wood veener, sheet steel or aluminum, fiberglass, phenolic, ABS or any number of other materials. The cores are typically honeycomb based (Plas-core or Nida Core type products) or an EPS/XPS foam based. Each has its advantages and disadvantages.
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I like this idea !