Plywood camper fabrication questions (thinking of idaSho)

[simple]

Ambition Strikes and Everlander welded an aluminum exoskeleton and glued panels inside of it. OEV does something similar I think, only they rivet the aluminum pieces together with plates on the corners. I don't know exactly how Aterra and Scout do theirs but they have aluminum on the exterior edges. I wouldn't call that a frame... but I guess you could.



Build many and have fun testing them!

I've seen one method for joining foam FRP panels that uses an inner and outer aluminum corner extrusion with a screw through the inside extrusion that pulls them together. There isn't much thermal bridging through the screw but the extrusion profile didn't allow for edge over lap so the corners of the panel lined up with each other and didn't offer great insulation in that area.

 

[simple]

Scout has some sort of thermal bridging going on because people complain about frost on the inside in certain locations of the camper. It's not a huge deal if the owner takes the time to thoroughly dry it out after use.

When we camp at the mountain, tons of snow gets tracked in and stays frozen on the floor until we get home. It then melts and runs out through the floor drain.

 

[rruff]

I've seen one method for joining foam FRP panels that uses an inner and outer aluminum corner extrusion with a screw through the inside extrusion that pulls them together.

Screws could be removed after the adhesive sets. Light aluminum angle in and out would be sufficient... maybe even overkill. Or you could use FRP angle. I've seen some panels made in Oz that used nothing but glue to join them at the edges. Since that apparently holds together (?), adding an additional exterior "edge guard" should be extra stout.

Styromax:

 

[simple]

Screws could be removed after the adhesive sets. Light aluminum angle in and out would be sufficient... maybe even overkill. Or you could use FRP angle. I've seen some panels made in Oz that used nothing but glue to join them at the edges. Since that apparently holds together (?), adding an additional exterior "edge guard" should be extra stout.

Styromax:

Cool video. Interesting construction method without added edge / corner reinforcement and extra sealing. Was OEV doing this on their small trailers? Also how do they finish the edges at the bottom of the box? Looked like exposed foam.

Regarding composite panel construction with edge extrusions. Something about a flat roof and extrusions around all the edges that make a 1/8" deep swimming pool on the roof bothers me. No plastic material and adhesive I know of is immune to degradation when it has standing water over time (on and off for several years) and in the PNW algae and other little things start growing and eating into it.

 

[ReluctantTraveler]

Regarding composite panel construction with edge extrusions. Something about a flat roof and extrusions around all the edges that make a 1/8" deep swimming pool on the roof bothers me. No plastic material and adhesive I know of is immune to degradation when it has standing water over time (on and off for several years) and in the PNW algae and other little things start growing and eating into it.

That's a really good point!