How To Make Side FLARES For A VAN? Anyone Build Their Own?

[magentawave]

I want to build side wall sleeping pods / flares for my 2005 Chevy Express / GMC Savana 2500 extended van so I can fully stretch out in my bed. . (I am 5’-11”.) You often see these flares / sleeping pods on Sprinters, Ford Transits and Promasters, but I have never seen them on “normal“ full-size vans like the Chevy Express / GMC Savana. The prices for flares are crazy expensive so I’d like to build my own. I have lots of experience fiberglassing surfboards, boats, etc. (polyester & epoxy) and was a custom cabinetmaker/finish carpenter for decades. I’m deciding between building them out of thin marine plywood or sheets of foam and then fiberglass the exterior.

QUESTION: Anyone build their own flares / sleeping pods? Can you tell me what materials you used to make them, please? Do you have photos?

Thanks🤙🏼

 

[dstefan]

Zero experience here, but Superfast Matt recently had a video on doing this on his YouTube channel. Maybe helpful, though he did use 3D printed sections to make the flares. Great channel, and quite entertaining if you’re not familiar with it.

 

[mog]

Zero experience here, but Superfast Matt recently had a video on doing this on his YouTube channel. Maybe helpful, though he did use 3D printed sections to make the flares. Great channel, and quite entertaining if you’re not familiar with it.

Link to save you a search -

 

[magentawave]

Link to save you a search -

Thank you. I will check it out.

 

[rruff]

I’m deciding between building them out of thin marine plywood or sheets of foam and then fiberglass the exterior.

Get some XPS foam from the usual places... glue them together to get the proper thickness and cut and shape them. Cover with plastic sheet or saran wrap, epoxy and cloth, let cure, remove the foam and plastic.

I'd recommend Ebond's cheap epoxy (slow cure) and 18oz plain weave cloth from Thayer Craft. Make sure to get the volan finish which is more flexible.