Good Ol' Aluminum?

[dzzz]

For sidewall and roof, how does aluminum compare to the modern plastics? I ask, because few commercial truck body builders use fiberglass, foam core and other favorite materials.
Some of these builders are very good and efficient at custom work. And many are not busy. So is there a good way to use their skills in making an Expedition camper? I'm talking about the frame and body of course. I would like the shell made and then do much of the remaining work myself.

 

[Mickldo]

For sidewall and roof, how does aluminum compare to the modern plastics? I ask, because few commercial truck body builders use fiberglass, foam core and other favorite materials.
Some of these builders are very good and efficient at custom work. And many are not busy. So is there a good way to use their skills in making an Expedition camper? I'm talking about the frame and body of course. I would like the shell made and then do much of the remaining work myself.

Aluminium makes a good camper body construction material. We build truck bodies and racecar trailers (see sig line) from alloy.

We use aluminium box section and hat section for the framework. We used to use alloy sheet for the outer skin too but have since changed to Di-Bond. It is lighter, stiffer, pre painted, and has good insulation properties. We glue this sheeting on with double sided VHB tape.

There are a couple of threads on here about Di-Bond and Aluco-Bond.

 

[dzzz]

Thanks. How easy is it to damage alucobond and dibond? Is the the equivalent to thin aluminum? Do you use plate aluminum in areas of potential damage?

 

[Mickldo]

Thanks. How easy is it to damage alucobond and dibond? Is the the equivalent to thin aluminum? Do you use plate aluminum in areas of potential damage?

Di-Bond is pretty impact resistant compared to thin alloy. The stuff we use is 3mm Di-Bond which is heaps lighter than 2.5mm aluminium and I reckon about similar strength to 2.5mm aluminium.

The plastic core of Di-Bond that separates the two alloy sheets provides good rigidity.

On the corners we fit an alloy angle corner capping. Most of the trailers we do are on road only but I suppose if you were worried about damage you could put a checkerplate wear plate in those high risk areas.

 

[dzzz]

Thanks. I'll see if I can find some dibond samples.
At this point I'm leaning towards an aluminum skeleton with the walls made with Nida-core foam filled panels. Although I may be less idealistic after totaling up the total cost of the Nidacore.......