Construction Method: Foam Sandwich / Composite panels? Good materials to use?

[TroySmith80]

I suppose "composite" can mean nearly anything. I'd like to build (we'll see if i can come up with the time to do it!) a lightweight and compact camp trailer, very custom. It doesn't need to be expedition tough, it won't venture too far off-road. One construction method that seems appealing is to use EPS (expanded polystyrene) construction/insulation foam panels for a core, with something else glued on each side to make a composite panel. I've heard of people using FRP (fiber reinforced plastic) panels for the out layers, and also i think aluminum sheet. I also am very, very CHEAP!

I'm wondering, would underlayment plywood (3-layered ~1/8" cheap plywood), lauan sheet, or hardboard would work well for the outer layers of the sandwich? Each of these is a fraction of the price of FRP or Aluminum, and they're probably lighter than FRP also. I think i might have to do some experimenting.

I've also seen people lay up fiberglass or carbon fiber over a foam core. That is an insane amount of time/effort and completely off the table for me. It makes for a great looking product, and probably very strong and long-lasting as well, but just way way too much time and mess.

 

[stomperxj]

You're going to have to fiberglass the outside if you use hardboard or lauan sheets too. No way I would ever trust either of those with just a coat of paint or even just a coat of epoxy. FRP or Filon on the outside would be the best option still in my opinion... Interested to see your experiments-

 

[SoCal Tom]

Over on tnttt.com, people are building small trailers with foam board, with luann on one side, and home depot canvas drop cloths and titebond 2 glue covered with house paint. It doesn't get much cheaper than that.
Tom

 

[IdaSHO]

I skinned my custom camper with 6mm meranti

The think is damn near bullet proof :snorkel:

I think I could have gotten away with 3mm, but the first time I ********** the thing into a tree Im sure Ill be happy with 6mm :Wow1:

epoxied, joints glassed, and painted.

 

[indiedog]

Sorry Troy, nothing to contribute. But I AM interested to see IdaSHO's build thread. :sombrero: Where would I find that please??? Construction method of ply/glass/paint sounds very similar to what I shall soon embark upon.

Edit: Did some sleuthing and found it over on Pirate. Rustoleum seems to be a popular choice for this type of thing. Also watched your video, you should be well pleased with your efforts.

 

[IdaSHO]

Yep, just google search IDACAMPER2.0 and you will find it.

That build thread should answer most questions.

 

[TroySmith80]

Thanks for the responses. I'll have to look into meranti, i've never heard of it. Also thanks for mentioning tnttt canvas/woodglue. I'd actually seen that before but had forgotten about it. Cool looking camper IdaSHO.

 

[jwiereng]

Canvas and titebond

IMHO the canvas titebond is not normally a smooth enough finish for road vehicles. The seams look like the dogs breakfast.