D.I.Y Light weight sleeper using D.I.Y rail top components

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D.I.Y Light weight sleeper using D.I.Y rail top components
This is a production trailer that uses side and roof tabs
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.I.Y Light weight sleeper using D.I.Y rail top components. Making my own profile of top rail. Will need to make one piece of tooling. This will be for a box trailer . Like the Weekender, Nano It will be 1320 Wide 2159 MM Long 1244.6 MM High. This will be for a box trailer with rear door. For the tooling. It will be the best to use something that has an inside curve with a flat bottom and side for tooling . Ponder a storage tub. The recesses will be 6.35 MM . Will use lot of photos.
This was used in 1950-60 Became
out of flavor when the fiberglass pull extruder came out.
http://www.expeditionportal.com/forum/album.php?albumid=3094&attachmentid=375601
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Il suffit de le faire

Thank you PCO6

What nice about building this way. It has gone on from the 1950's

Tooling has a very low-cost.

What is fiberglass rail top modular fiberglass component framework? The simple answer is external framework pieces, with tabs. The tabs are at 90-degree to each other.

Think of a box. The rail top modular fiberglass components will be used to fasten top and sides together.

The best way to picture this is look at a You Hall trailer.

There are several places to buy from. What if you like to build a trailer where the external frame matches the top of your truck bed? Maybe you like the look of an external frame trailer. I will post a bit about making some tooling it not hard to do . The trailer I will be building is a very light weight box sleeper.

When making any tooling that need a 1/4 inch lip and using an inside are outside curve on the tooling. You will find the fastest and best costing is using this. http://www.homedepot.com/p/Woodgrain-Di ... /206178822

In the shop we have a TRA Panel Test System. I placed one rail top 12 inches in length that had been foamed injected. With sheet foam & foam in a can. With a 2.54-cm die. One inch. Received sounds at 106 pounds, bulging at 135, cracking at 157, failure at 186.
As I plan to be as detail that possible. . Making the part it shelf .Use of rail top pieces as semi- monocoque compressive structure

TRA Panel Test System is a destructive test. Pressure is applied to one inch, then measured . Failure at 186 PSI consisted of the top tap moved a half of an inch. As the trailer is - monocoque structure .You should be able to install A 500 pound load on the roof

The fastest way to build is to bounded all the small pieces in to one long one. Marked out where the bends are placed.

The long pieces placed on the floor north to south. At the angles you dived by two_One haft marked to the right the other to the left of a 90 right angle. Then cut to what is the top. removed the cast off bending to the right angle. Using panels clamps to hold for bounding. The time to cut for a ten foot weekender. For the two sides .Under one hour.

For the jeep people look at old bath tubs. trash basket at 99c store It has the older jeep profile .

If you have a hard time getting your head around this. Take a box .Place some tape two inches from the bottom on the inside side.On the bottom of the box place tape two inches from the side .If you pulled a part it will have the reset lip
 
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Sorry to thous that have been looking on. I post pictures then they disappear. Working on this. .A gain this was done in the 50's.
It has moved to trailers like www.expeditionportal.com/forum/threads/163240-Overland-Explorer-Composite-Off-Road-Trailer
What make This fast is the way the top rail is cut .Hinged using the cut & hinge it locks one plane .So it is just bent. When I did the angles . I cut each piece one at a time .So when making the angles had to fight to keep true. Also had three bound lines.. Had six hours of work in making the two sides. Using the cut & hinge. It would be under one hour. There no hard BS tooling to be made. the main thing When making any tooling that need a 1/4 inch lip and using an inside are outside curve on the tooling. You will find the fastest and best costing is using this. http://www.homedepot.com/p/Woodgrain-Di ... /206178822.
There a lot of misinformation about building this way . this been done from the 50s .
if you look at https://www.youtube.com/watch?v=3erMv_MF4o4 Chuki Teardrop Caravan .It's built using the tabs.
This about you build your own rail top .It so easy. After 60years all the bugs have been work out..The way this is built is using railtop made like sandwich panels
http://forum.expeditionportal.com/attachment.php?attachmentid=387220&d=1487486469[/URL
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hyttp://www.expeditionportal.com/forum/attachment.php?attachmentid=377061&stc=1&d=148056924
Trying a picture . This is how I marked the rail top to cut the first bend. Mark a 90% where the bend center need to be . if you wanted a 60% like on the saw tooth trailer. You will cut 30% to the front of the 90% then 30% to the rear on the 90. Leaving what will be the top to be the hing point.. This is a sandwich panels style build. You can buy all day structural profiles an the web /eBay/Amazon.
There built to heavy. . The foam sandwich panels as the frame is what make this a great way to build. So I hope the pictures come out
 
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This sleeper turn out to be 2184mm / 86'' The outside height is 1338.5 /52.5 the width is the same as the height. The inside is less 1'' foam in roof /two'' to cover frame /1.5'' foam for floor = 48''
The red is just gel-coat .As the many small parts are bond together so will need to be primed and panted.
 
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Working on pictures . Sorry .As this from of constructing is over 60 years old. I'm sure you have seen before
I've had a few ask is the top-rail for purchases and how much.
I's so easy to do .make your own.
If to buy .I see kits that have five pieces of woodply for$900 -3000
A planed fiberglass rail kit. for $ 2599. With only one crosses top piece and no bottom skirt .My thinking is best to do it yourself.
To me for what is shown here would be no more $600-$800 .Looking at the cost of fiberglass fenders.
 
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Trying pictures again . This is so cheap .Been going on for 60 years all the bugs have been work out.This is the same thing as http://www.expeditionportal.com/for...ot-modular-trailer-topper-building-components you can do all your tooling for under $6.00 .All the reset are just made from 1/4 lath from home depot in the tooling . I found heaver modular-trailer-topper-building-components on line this shell would cost under $300. The fiberglass part that goes for the price of under $ 300 are a bit heave . So you might Email them and see if they perform a lighter one. Try to email them no reply at this time.
Using the foam works great . one start up could not make there component work. Now they know about the foam .There going after it again
 
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I';m so sorry been held up .IT'S wet and cold here .Back home It is a lot colder but dryer snow.
Trying pictures . They down load then latter disappears. As if something is removing them


I have dragged my heels to see how well bobwhite215 Aluminum composite teardrop build
_http://www.tnttt.com/viewtopic.php?f=50&t=67211 works out.


I had many ask if I am using tabs .To hold the ends together. Not on the style I an using.There some very bad information being put out. About this way of building .By people who know better . .Body feller /Bondo .Has no strength are adhesion . Even on the can post no more than 1/4 inch deep.


I have been informed the parts on E-bay cuts their side tabs off when performing a trailer build
 
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Will try this for pictures
This way of assembling is so easy cheap . bee` around for over 60 years this is the same as the so called TrailTop fiberglass components. The tooling should not cost more than $10.00 USA dollars to build.
 
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A 18 wheeler back in to the trailer.Pushed it a little over 20 feet, Rolled over one time.Just the shell with no wall ,roof.
The floor had been bounded in part way It need the foam injected. The floor was in two pieces. Just a few rips in the glass on two uprights Some road rash . Will post pictures soon of damage
I been working with a different shop that dose compression tooling ..Work on putting the tab inbound .That way you can use any infill for the sides . Also you can cut the side wall larger .It will be behind the fiberglass . Will improve keeping water out .
]http://forum.expeditionportal.com/attachment.php?attachmentid=387225&d=1487486701
 
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À jour, j'étais aux anges. Reçu mon premier rail compression top pièces. Une boîte de colle ensemble. Ajouté des feuilles de métal 16 gage d'agir comme un mur extérieur collés par le PL Premium (merci Bill) rruff,repas feuille de fibre de verre .lieu dans un four à 100f après trois heures supprimées . Abandonné sur le sol. Métal et fibre de verre séparés.. Dans le côté de la rampe de compression top est très lisse. High tech moyen de corriger ajouter balle sacs poubelle..pour rendre le cadre est le même que le rail haut. Besoin d'un nouveau nom pour les deux.


Ce sera la même coupe et la charnière . La grande chose, c'est avec le C en haut . Il n'a pas besoin de la dose au centre d'être préfet coupe.
 
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