How to build your own Carbon Fiber Camper making your own Composite/Foam panels.
- Thread starter ebrabaek
- Start date
ebrabaek
Adventurer
Been a looooong road, or at least it feels like it but the box is ready for a wash down and then top coats, which means that next week some time I will crown my truck with a new camper shell.... Whoooooheeeeee.
Gas struts works amazing. This time there is no flex at all so this was definitely the right fix. They close perfectly with 18mm to spare. FYI the struts are 17 inch full length and 9 compressed with a 22 pound rating each.
Then it was time for the big and scary dig. Cut a giant hole in the front for the window.
I think I measured 5 times, even taped the frame on to make sure.
Ready........
Set..........
Cuuuuuut......
Then as usual, the edges had to be locked in place with THIX......
Gas struts works amazing. This time there is no flex at all so this was definitely the right fix. They close perfectly with 18mm to spare. FYI the struts are 17 inch full length and 9 compressed with a 22 pound rating each.
Then it was time for the big and scary dig. Cut a giant hole in the front for the window.
I think I measured 5 times, even taped the frame on to make sure.
Ready........
Set..........
Cuuuuuut......
Then as usual, the edges had to be locked in place with THIX......
ebrabaek
Adventurer
I am not a painter. If you have seen any of the other pieces I have created then you already knew that 
. The solo purpuse of the top coat is to protect the epoxy. I actually prefer the satin texture the box was before paint. Scored and washed, ready for paint.
@ the very modern paint booth with winds at 2-3 KTS at the ready.
2 coats in....
Back inside.
I am intentionally spraying fast to avoid too much wet up. I really wanted it to be more satin, but with 4 layers on there it wont yield that result. I am very happy with it as it will serve its purpose, and I am not trying to create a museum show piece, but a functional overland camper shell.
Tomorrow the front window goes back in and it will get installed on the truck. Big day indeed.
. The solo purpuse of the top coat is to protect the epoxy. I actually prefer the satin texture the box was before paint. Scored and washed, ready for paint.@ the very modern paint booth with winds at 2-3 KTS at the ready.
2 coats in....
Back inside.
I am intentionally spraying fast to avoid too much wet up. I really wanted it to be more satin, but with 4 layers on there it wont yield that result. I am very happy with it as it will serve its purpose, and I am not trying to create a museum show piece, but a functional overland camper shell.
Tomorrow the front window goes back in and it will get installed on the truck. Big day indeed.
ebrabaek
Adventurer
It is on the truck...... But first a few small things. The trim ring that I got for the forward window did not work, but I was expecting that as it is for a 1/8 inch thick wall and mine is just over 1/2 inch thick. Off to the depot to pillage a flat bar of aluminum. Painted and in place. That'l do.
Window in....
On the truck....
Now begins the end game. I am about 99% sure I will dull the finish with a non abrasive pad. Sau 2-3000 grit. It is way to shiny for me. Hinge needs to be countersunk a few millimeters, etc....etc...
It has been a joy to put this together and I know that there is lots more to come. As it has a 7.2KV a/c power onboard, I decided to go the 115vac way with the compressor, so that needs to go in the corner, but I can now take a deep breath. When I began It was not my intention to post the whole build here. Just how to make the panels, but I am glad I did, as just about everything in here can be used very constructively to make your own box. Even though yours might be a lot bigger...... Fire away with any questions you might have.
Window in....
On the truck....
Now begins the end game. I am about 99% sure I will dull the finish with a non abrasive pad. Sau 2-3000 grit. It is way to shiny for me. Hinge needs to be countersunk a few millimeters, etc....etc...
It has been a joy to put this together and I know that there is lots more to come. As it has a 7.2KV a/c power onboard, I decided to go the 115vac way with the compressor, so that needs to go in the corner, but I can now take a deep breath. When I began It was not my intention to post the whole build here. Just how to make the panels, but I am glad I did, as just about everything in here can be used very constructively to make your own box. Even though yours might be a lot bigger...... Fire away with any questions you might have.
ebrabaek
Adventurer
The clearcoats I use is always spray on. I have done some urethane on wood. What are you covering, and what is the purpose of the clear coat??
You wouldn't happen to know of a decent clear coat I can use... that can be rolled or brushed on, cures quick, and doesn't stink too bad? This will be interior and rarely exposed to sun.
ebrabaek
Adventurer
Raw carbon , to me is straight off the roll, not infused with epoxy, but I think you mean the carbon layup (carbon+epoxy) that you want coated with a finish?? Some of the 2 part coatings are thick in nature and needs a thinner agent to be able to spray them. I wonder if that would work as the thin viscosity is what makes it dang near impossible to brush on. I would stop by an auto coatings and paint supply store and chat. Up here they have been very helpful and Im sure the same is the case in NM.
ebrabaek
Adventurer
As mentioned, it is now time to fine tune the camper. As with anything you create from a piece of paper, it is a complicated process, and the propperbility of needing to go in and fix, improve or expand, is fairly high. This is no different. I have identified 4 things that needs remedy'ing. 1 I was expecting. 1 I was not, and the last pokes its ugly head up once in a while.
They are as following.
1) Rear door to truck tail gate interface. I knew of this one, but did not have a solution of full design at the time of built, so I decided to get the lower flange within 3-5mm of the truck tail gate and go from there.
2) Some one asked if I had delam. There are about 5 small 2x3'ish patches that have experienced thermal delam. As the truck is parked in the sun the temp of the skin does go in the range of 150-175 deg. F. Any air pockets in the matrix will expand, lifting the skin ever so little.
It is almost impossible to create a panel as I did, or outside a hydraulic or vacuum press to not have small voids. Specially when you are conscience of resin to fiber ratio's. I treat them as norm and part of the deal, so I will show you how to stop them in their tracks.
3) The two sharp forward top corners are bugging me a bit. The 2023 F-150 is stoopid quiet. 80MPH on the freeway and quiet. On the maiden trip we had a freeway haul to a wedding that put us 10 miles into a 40 mph headwind, and I heard just a little wind noise. Curse you, quiet truck..... The fix is what will make you spit out the double expresso all over the computer screen, and perhaps make you think I'm lagging a few chromosomes....... I'm gonna cut them corners off with a saw...... I think..... I really do....... I think.
4) Countersink the hinge on the door about 2mm to get a bit more pressure on the big wiper seal.
Stay tuned
They are as following.
1) Rear door to truck tail gate interface. I knew of this one, but did not have a solution of full design at the time of built, so I decided to get the lower flange within 3-5mm of the truck tail gate and go from there.
2) Some one asked if I had delam. There are about 5 small 2x3'ish patches that have experienced thermal delam. As the truck is parked in the sun the temp of the skin does go in the range of 150-175 deg. F. Any air pockets in the matrix will expand, lifting the skin ever so little.
It is almost impossible to create a panel as I did, or outside a hydraulic or vacuum press to not have small voids. Specially when you are conscience of resin to fiber ratio's. I treat them as norm and part of the deal, so I will show you how to stop them in their tracks.
3) The two sharp forward top corners are bugging me a bit. The 2023 F-150 is stoopid quiet. 80MPH on the freeway and quiet. On the maiden trip we had a freeway haul to a wedding that put us 10 miles into a 40 mph headwind, and I heard just a little wind noise. Curse you, quiet truck....
. The fix is what will make you spit out the double expresso all over the computer screen, and perhaps make you think I'm lagging a few chromosomes....... I'm gonna cut them corners off with a saw...... I think..... I really do....... I think.4) Countersink the hinge on the door about 2mm to get a bit more pressure on the big wiper seal.
Stay tuned
ITTOG
Well-known member
With appologies, I am glad this build is not complete.As mentioned, it is now time to fine tune the camper. As with anything you create from a piece of paper, it is a complicated process, and the propperbility of needing to go in and fix, improve or expand, is fairly high. This is no different. I have identified 4 things that needs remedy'ing. 1 I was expecting. 1 I was not, and the last pokes its ugly head up once in a while.
They are as following.
1) Rear door to truck tail gate interface. I knew of this one, but did not have a solution of full design at the time of built, so I decided to get the lower flange within 3-5mm of the truck tail gate and go from there.
2) Some one asked if I had delam. There are about 5 small 2x3'ish patches that have experienced thermal delam. As the truck is parked in the sun the temp of the skin does go in the range of 150-175 deg. F. Any air pockets in the matrix will expand, lifting the skin ever so little.
It is almost impossible to create a panel as I did, or outside a hydraulic or vacuum press to not have small voids. Specially when you are conscience of resin to fiber ratio's. I treat them as norm and part of the deal, so I will show you how to stop them in their tracks.
3) The two sharp forward top corners are bugging me a bit. The 2023 F-150 is stoopid quiet. 80MPH on the freeway and quiet. On the maiden trip we had a freeway haul to a wedding that put us 10 miles into a 40 mph headwind, and I heard just a little wind noise. Curse you, quiet truck....
4) Countersink the hinge on the door about 2mm to get a bit more pressure on the big wiper seal.
Stay tuned
rruff
Explorer
Thank you! Yes that is correct... uncoated carbon-epoxy.