Foam sandwich composite cabinets

[Jb1rd]

Came across these video on YT and though that is was pretty freak'n cool idea for a DIY build out, I hope you do too!!!
The van:
https://www.youtube.com/watch?v=u_VUpd3t6ew
The method:
https://www.youtube.com/watch?v=ucf2FVIdr1Q

 

[86scotty]

Interesting. I'd like to see the video on how they do the finish work on the outsides but I guess it's not out yet?

 

[Jb1rd]

Here ya go Scotty
https://www.youtube.com/watch?v=qiI0AnPPySg

Interesting. I'd like to see the video on how they do the finish work on the outsides but I guess it's not out yet?

 

[VOODOO7.3]

The foam cabinets are a cool idea, but I'm wondering why not just start with high R foil faced foam. The foil is on both sides and provides plenty of extra tension strength against bending. There's also a caulk gun applied foam adhesive that works well for this. Skipping the whole screen deal would cut build time in half.

 

[Mwilliamshs]

The tensile strength of foil is pretty low. The screen is quite strong, especially for its weight. Self-adhesive vinyl would probably split the difference and speed assembly considerably.

A tough, attractive wallpaper would be a one-step solution.

The flammable nature of foam insulation makes me think it needs a non-combustible outer layer added

 

[luthj]

A nomex fabric would solve the tensile strength and fire retardant issues.

 

[Jb1rd]

I used to sale SIP panels and here is what are manf. had to say about combustion/flammability;
"Polyurethane has better fire, flame, and smoke characteristics. Polyurethane does not melt at any temperature. It will withstand constant service temperatures up to 180-degrees Fahrenheit and will not char up to 275-degrees Fahrenheit".

As part of a demonstration we would use a torch and have a tech put it on one side of the PU and their hand on the other side (this was for a 4" thick wall but the principal is the same) it is quite remarkable that 1. it does not transfer heat and 2. it does not melt or burn like a polystyrene foam will.

The tensile strength of foil is pretty low. The screen is quite strong, especially for its weight. Self-adhesive vinyl would probably split the difference and speed assembly considerably.

A tough, attractive wallpaper would be a one-step solution.

The flammable nature of foam insulation makes me think it needs a non-combustible outer layer added

 

[Mwilliamshs]

Nomex is a great idea. I found a color and pattern I think I'd like on eBay for $14/yd (36" x 61").

Polyurethane is better than polystyrene from a combustible perspective but the propane stove in most vans has a 3500°F+ flame. The flame of a burning paper plate is about 1,500°F. I would NOT want exposed or even insufficiently protected foam of either type as a permanent fixture in my van. If a foam cup burns, put it in the sink or throw it outside. If your cabinets burn...uh...that's bad.

 

[dazdconfsd]

Nomex is a great idea. I found a color and pattern I think I'd like on eBay for $14/yd (36" x 61").

Polyurethane is better than polystyrene from a combustible perspective but the propane stove in most vans has a 3500°F+ flame. The flame of a burning paper plate is about 1,500°F. I would NOT want exposed or even insufficiently protected foam of either type as a permanent fixture in my van. If a foam cup burns, put it in the sink or throw it outside. If your cabinets burn...uh...that's bad.

If the inside, unfinished (per the video method) edge gets exposed to fire, I think you'd have other issues already. I'm not sure how much difference the type of fabric used would matter since it's covered in several layers of other materials anyways.

 

[Mwilliamshs]

If I built them I'd wrap fully. Small extra expense upfront vs big gain in durability.

If using a wrap with a finish you like, any extra layers would be superfluous.

A (fabric friendly + foam friendly + people friendly) glue sprayed/spread on + a nomex pattern you like = done.

 

[TeleSteve]

I suppose you could also wrap the foam in a laminate (like Formica) it would add the needed tensile strength. Trimming it would be a little tough, but you could oversize the pieces, adhere the front and back and then cut the panel to size before adhering the edges.

 

[Paul E Dude]

I started to make a set of small wall cabnets for my van. $12 foam $20 paint $15 screen. and a few days work so far. Hate them. Im going to quit and go buy some Plywood.

 

[Jb1rd]

If you don't mind could you please expand on what is that you don't like? The process, the result, the performance, etc????? Care to share a picture or two of your attempt? I think it could be valuable for those of us who are looking at this as a viable contender/alternative to ply cabinets. Cheers and good on ya for at least giving it a go!!!

I started to make a set of small wall cabnets for my van. $12 foam $20 paint $15 screen. and a few days work so far. Hate them. Im going to quit and go buy some Plywood.

 

[Paul E Dude]

The fiberglass screen wouldnt stay in the corners when I folded them. The foam was $12 screen $10 Then the paint $20.. Plywood and regular paint is cheaper.

 

[DAV!D]

The other issue with these foam cabinets, is if you are carrying anything in your van like say you toss a bike in there. If it falls and hits the cabinet, it's going to do a lot of damage vs wood that might just get scratched up.