Victorian
Approved Vendor : Total Composites
For some reason it sounded like you are just building this for yourself, not starting a business.
Designing and Building My Own "Earthroamer", a story. (with photos)
- Thread starter mwtownsend
- Start date
ITTOG
Well-known member
Sounded the same to me but I just saw this article.
Ever Overland Introduces the Ever Expedition Shell - Expedition Portal
Ever Overland has launched the Ever Expedition Shell, a composite shell and subframe for the Ford F-550, built for pros and serious DIY overland builders.
expeditionportal.com
Then noticed I missed this.
mwtownsend
Member
Both are true. I wanted to build a 550 expedition vehicle and the only way to justify the up front cost of moulds was to make shells available to other up-fitters and DIY adventure enthusiasts. My post shows my personal build.
mwtownsend
Member
The shells come without any cutouts aside from the entry door and fixed skylight - those are generally handled by the person / company doing the finish out. The cargo doors aft of the rear axle are set but all other cutouts (aside from the entry door and fixed skylight) are handled by the company doing the inside finish out. Hope that helps!
waveslider
Outdoorsman
Damn
Yes, this helps. What is on the forward left side of the box since I there doesn't seem to be any storage there. Would I be able to visit your facilities in Fort Worth?
SootyCamper
Active member
Not trying to downplay your achievement. Offering shells of this caliber is awesome!
However, with all that hard work and premium features you then utilized the Alibaba China (Tern) non thermally efficient "euro" door? Those doors condensate like crazy.
What was the thought process there, looks like you used premium outbound type windows, why deviation on the entry door?
However, with all that hard work and premium features you then utilized the Alibaba China (Tern) non thermally efficient "euro" door? Those doors condensate like crazy.
What was the thought process there, looks like you used premium outbound type windows, why deviation on the entry door?
mwtownsend
Member
Hey SootyCamper, We'll test the doors more once we're conditioned inside but the shell of the door is a block of foam with an aluminum skin and a double paned (acrylic) lite. There's a few companies on Alibaba making very similar doors and I feel good about this one but if there's issues, we'll address it. We used an off the shelf component because there's only so many hours in the day... We're also posting updates on our IG and YouTube as we have them. Thanks for the feedback and kind words. They're greatly appreciated!
mwtownsend
Member
That's actually a super deep storage well; it's like close to 20" deep. I'm using it for my 42gal gray tank. For sure! Come visit us in FW; it's an easy flight into DFW. We hosted two groups last week; reach out if you want to setup a quick trip-
mwtownsend
Member
Thanks, Waveslider; is that your rig in your profile pic?
waveslider
Outdoorsman
It is.
mwtownsend
Member
Been a while, still building my camper out - here's some update photos -
Cabover
Bathroom (you can see where sink will go)
Dining Area / Bedroom 2
PET walls lookin' nice with the shadows
We used aluminum tubing to support our dinette area, kitchen as well as bathroom walls.
These sections are attached with rivets and then fiberglassed into the body to create a strong bond that will support the constant vibrations in the shell.
Walls
Bathroom walls are ACM aluminum backed polypropylene sheet, typically used for sign making. They're a bit sturdier, cut easily like the PET panels and have great moisture resistance.
Ceilings, cabover and non cabinet walls are PET panel material made from recycled plastic water bottles. Feels a bit like felt. These materials were left over from another build and worked perfectly in this application. These help reduce sound, add a tiny bit of insulate value, they're easy to cut and place and they look nice! We used a backing piece to allow us to cut screw flaps which would conceal the attachment points but make them accessible later.
Cabinets and wood furniture are going in next, will share those photos as soon as I have them.
Cabover
Bathroom (you can see where sink will go)
Dining Area / Bedroom 2
PET walls lookin' nice with the shadows
We used aluminum tubing to support our dinette area, kitchen as well as bathroom walls.
These sections are attached with rivets and then fiberglassed into the body to create a strong bond that will support the constant vibrations in the shell.
Walls
Bathroom walls are ACM aluminum backed polypropylene sheet, typically used for sign making. They're a bit sturdier, cut easily like the PET panels and have great moisture resistance.
Ceilings, cabover and non cabinet walls are PET panel material made from recycled plastic water bottles. Feels a bit like felt. These materials were left over from another build and worked perfectly in this application. These help reduce sound, add a tiny bit of insulate value, they're easy to cut and place and they look nice! We used a backing piece to allow us to cut screw flaps which would conceal the attachment points but make them accessible later.
Cabinets and wood furniture are going in next, will share those photos as soon as I have them.
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