composite sandwich construction

[somewhereinursa]

I'm new here and hope that this is the correct section. If not, please let me know which section I should post in.

I'm interested in building a small expedition camper similar to the Turtle V and would like to know where I can purchase SCS (structural composite sandwich) panels and angles.

Does anyone know where GXV etc., purchases their composite panels and angles?

Gary Wescott used Nida-core for the Turtle V but has had problems due to the thermal expansion between the aluminum and Nida-core.

I'm in the process of designing a camper in Autodesk Inventor and need to find the panels and angles before I can proceed. I would like to match the angles on the Turtle V, if possible.

Any help would be greatly appreciated.

 

[adam88]

The angles they used were just aluminum angles, probably something like this: http://www.metalsdepot.com/products/alum2.phtml?page=aangle&LimAcc= &aident= in a 4" x 4" x 3/16" or something.

As for the composite panels, their issue wasn't with the nidacore it was with fiberglass bonding to aluminum in general. However, I think that problem has been mostly solved with sikaflex 252. Apparently a lot of their problems came from the camper manufacturer they originally used in Richmond BC (shoddy work). According to them, no adhesive at all was used on their original camper (the walls just sat in the aluminum slots). They had a ton of leaks from this until they added their own 3m adhesive. I think their issue would have been a non issue had it been done from the start with sikaflex. However, both Gary and Monika said their next camper would use fiberglass angles instead of aluminum angles.

There are a few manufacturers around the US who make foam with fiberglass on the outside, just depends what you are looking for, thickness, and cost, etc. Gary and Monika used 1/8" fiberglass on each side, and 1.5" insulation. Some people go with 2" or just 1", like I am going to, to keep the walls thinner.

 

[somewhereinursa]

Thanks, that's what I needed to know.

 

[shachagra]

I am building a topper for a 4X4 van using home built foam core panels with great results. I started a thread on the 4X4 van section, "Jackur" if interested. I am a fan of bonding the edges with biaxial mat and glass, there is no seam to leak, but it it very labor intensive.

 

[ersatzknarf]

There are a few manufacturers around the US who make foam with fiberglass on the outside, just depends what you are looking for, thickness, and cost, etc. Gary and Monika used 1/8" fiberglass on each side, and 1.5" insulation. Some people go with 2" or just 1", like I am going to, to keep the walls thinner.

Hi Adam,

I have been looking and looking, please can you advise who those "few manufacturers around the US" are ? The closest I have gotten is "NidaFoam" (http://nida-core.com/english/nidaprod_lamin_comp_nidafoam.php) and cannot find out much more even from their website and their sales email address seems to be gone (since they have become part of 3M ?). It states the panel size is "10x50" but no indication as to the unit of measure. If it's inches or cm, it's not the 4' x 8' (or larger) one would hope for. If there's someone out there making fiberglass skinned foam core panels at a somewhat reasonable price, one would hope that the market would beat a path to their door...

Thanks !

 

[adam88]

Hi Adam,

I have been looking and looking, please can you advise who those "few manufacturers around the US" are ? The closest I have gotten is "NidaFoam" (http://nida-core.com/english/nidaprod_lamin_comp_nidafoam.php) and cannot find out much more even from their website and their sales email address seems to be gone (since they have become part of 3M ?). It states the panel size is "10x50" but no indication as to the unit of measure. If it's inches or cm, it's not the 4' x 8' (or larger) one would hope for. If there's someone out there making fiberglass skinned foam core panels at a somewhat reasonable price, one would hope that the market would beat a path to their door...

Thanks !

Hi Frank,

Sorry for the late reply. There are a few... I think the trouble is they all seem to deal with big customers and it is tough to get them to do small orders. Here was a list posted by westwys in another thread. No idea how many of these are still valid:

Composites
http://www.amerimaxbp.com/home
http://www.rhinokore.com/products.html
http://www.ccvbc.com/composite_panel_systems.html
http://www.cranecomposites.com/facilities.asp
http://www.bellcomb.com/rail.aspx
http://www.portafab.com/aluminum_honeycomb_panels.shtml
http://www.ebertcomposites.com/contact.html
http://www.monopan.ca/

 

[ersatzknarf]

Hi Frank,

Sorry for the late reply. There are a few... I think the trouble is they all seem to deal with big customers and it is tough to get them to do small orders. Here was a list posted by westwys in another thread. No idea how many of these are still valid:

Composites

Hi Adam,

No worries :sombrero:

Thanks for the reply. I had seen that list from Yves' thread, but had forgotten about it. Thanks. Yes, you are right. They most likely do not want to deal with small orders for a one-off. I had sent a note to Rhinokore, recently, and had gotten a very nice and quick response. However, once I clarified that it was for a one-off camper cabin build, all communication stopped

I've also tried CCVBC and Monopan...

It would be great if there were dealers in these materials, so that one could make a single project, but as you said, they are really set up for big order customers, so dealing with the manufacturer is not easy.

Unfortunately, I think the window of opportunity is closing for me, so will bide my time for now.

Thanks, again.

 

[adam88]

Hi Adam,

No worries :sombrero:

Thanks for the reply. I had seen that list from Yves' thread, but had forgotten about it. Thanks. Yes, you are right. They most likely do not want to deal with small orders for a one-off. I had sent a note to Rhinokore, recently, and had gotten a very nice and quick response. However, once I clarified that it was for a one-off camper cabin build, all communication stopped

I've also tried CCVBC and Monopan...

It would be great if there were dealers in these materials, so that one could make a single project, but as you said, they are really set up for big order customers, so dealing with the manufacturer is not easy.

Unfortunately, I think the window of opportunity is closing for me, so will bide my time for now.

Thanks, again.

Hi Frank,

No problem. My plan, since I live in BC (like westyss) is to drive directly up to Rhinokore and place my order in person. Maybe bring them some donuts or something, lol. I think if I do it during the winter, it is more likely to get done, as they will probably be less busy than in the summer when construction projects are taking place. Here's hoping.

Adam

 

[ersatzknarf]

Hi Adam,
Good that you are in the right location and winter should make for good timing, too.
Timmy's coffee and doughnuts should do it
Fingers crossed that it all works out for you ! ! !