A disheartening occurrence occurred. I'm knocking out a kitchen table out in the garage for the wife and then was going to switch gears to completing the lower half shell. I had the door open on a nice sunny winter day and the sun was hitting the front nose of the camper, the surface got quite hot to the touch and I can see a couple delamination bubbles.
Though I almost want to say they were in areas that delaminated during fabrication with the heat blankets so not sure if there is something else going on there I'm overlooking.
At this point I'm stewing on the implications. I'm leaning towards taking the painted top half off and setting it out in the sun and seeing what happens. If its just those spots that are of issue I'll likely drill two holes in each and inject epoxy from one hole to vent out the other just to back fill and support the skin. If it happens all over, well that just sorta sucks... I can live with a couple cosmetic bumps I had to back fill at this stage if that's all it is, mass delamination would mean structural instability though.
Doing some reading sounds like there are gasses trapped in this type of foam (extruded polystyrene) that expand when heated up. For any future builders not sure if cooking the foam ahead of time would have mitigated this (not that it would be practical) or not. One more reason, other than time, to have started with engineered panels ideally, hindsight 20-20 to have searched harder than I did.
I flipped the top back onto the bottom to double check the fit (and I want to do a trial run with actuators before coating in case a problem needs a structural modification). I pulled all the peel ply as well so I can start the rough fairing. I found a couple areas where the heat blankets bubbled up things on me which was concerning, so I ran a little test to see what kind of heat I was dealing with. I put a sample piece in a moving blanket with a temperature probe on the surface and put a doubled up heat blanket over it. Turns out it could heat the glass surface up to 170F! So at high temps there is concern over a bubble forming under the glass and a pocket of delamination but hopefully its not a realistic issue under normal conditions (esp. with light paint colors). Westss had a delam in his rig due to the high heat thrown off by his catalytic heater but hasn't had issue with normal environmental stuff (though I would guess his rig is likely a polyurethane core so not quite apples to apples). Anyways not sure if I'll try injecting epoxy into the bubbles and push them down or sand out and re glass those areas. Injection would be easier, I think, but I'd be pissed later if those areas lifted again down the line...
Anyways some pics w/ some repair areas to correct circled (hard to see with some of the other marks I had to help orientate the fabric):
