DIY Composite Flatbed Camper Build

[Terra Ops]

I made the bathroom walls prior to the roof going on. This was easier bonding than with the roof already in place.
Any thing that can be bonded to the inside of the box will increase overall strength.
I used 1/2" foam from home depot. After lamination, a 3/4" aluminum c channel also from home depot or lowe's was used around the edges. I used sika for this as well as bonding to the camper interior.

 

[Terra Ops]

For the odd angles/joints I took a small stick of aluminum and bent it over the corners where needed, then took to a metal shop where they cut and bent the aluminum to my specs.
It fit perfectly. This too was needed for the inside.

 

[Hummelator]

This looks great. A while back I was considering a sandwich panel for the trailer I was building but was unsure if it would be strong enough. I had originally plans on 1 1/2" ridged foam sandwiched by 2- 1/16 thick sheets of aluminum.
Seeing this thread I may have to source out some fiberglass skin...

 

[Recce01]

nice!

 

[calicamper]

Really nice. One of my sailing buddies Antrim Composits. Number one thing builders can do to increase composit strength is high quality Resin. Sounds like you figured that part out pretty quick. Looks great!

 

[getout]

Really cool. Thanks for posting all the pictures. I especially like the creative clamping. Can't wait to see more.

 

[Terra Ops]

Thanks for the comments.
One thing to note, with the ability to make your own panels, the applications are numerous.

Here are some more pics during assembly;




Like I said, never done this before. Angles do not always
come together perfectly, but I have found there is a lot of room
for forgiveness. Before and after some aluminum touch up

 

[Terra Ops]

Made jack mounting brackets out of aluminum.
Since these points will take the most stress when lifting, I had planned on bolting
all the way through to the inside. However, this did not work out since I used a smaller
L bracket "3inch" instead of 4. I needed a right angle to fit snug against the 4 inch exterior.
They only make 3 inch. Had I gone to 4, the inner angle would curve and not fit.
I ended up attaching by using the Sika and stainless lag bolts to attach the brackets
to the exterior L channel.
I had my concerns, but after lifting and mounting the camper, I felt better.

 

[Olbuford]

Very cool. Nice job! Looking forward to seeing more of the build.

 

[rruff]

First step was to locate the fiberglass skin. This actually took longer than I thought it would, but found a manufacturer practically in my own back yard. http://www.vetroresina.com/?lang=us

Love your build! I considered something similar, but ended up going with hand layup on 20 psi Foamular, so I could do curved surfaces. I used the cheap foam because I couldn't find anyone willing to get the 60 psi foam locally, and shipping would have doubled the cost.

What are the specs for the skins you are using? Thickness, weight? FG, polyester resin with gelcoat?

 

[Terra Ops]

Love your build! I considered something similar, but ended up going with hand layup on 20 psi Foamular, so I could do curved surfaces. I used the cheap foam because I couldn't find anyone willing to get the 60 psi foam locally, and shipping would have doubled the cost.

What are the specs for the skins you are using? Thickness, weight? FG, polyester resin with gelcoat?

 

[rruff]

Thanks, looks like good stuff and the price seems very reasonable.

 

[Terra Ops]

Thanks, looks like good stuff and the price seems very reasonable.

Yeah, learned a lot about panels over the last year. Not too many manufacturer's want to deal with the little guy and the one that does ships it in from China.
Vetroresina had no problem selling product to me. Very happy with the results. Some times you just have to do it yourself

 

[Terra Ops]

After the lifting test, I proceeded with the remaining window install

Really have to watch that saw blade, not much room for error here

 

[Terra Ops]

Here are the latest interior pics, just got the dinette cushions ordered today