US based box builders

[S2DM]

Hey All,

I think we've decided to ditch our ambulance box in favor of a composite solution for multiple reasons. We are considering a pre-built solution that's substantially more than we'd budgeted, but are wondering if there are any independent builders making Nida-core style composite, shells only (we'd like to layout and outfit the interior ourselves). Basically folks building high strength shells you can lay out how you'd like. Trying to stay well south of 50k for the shell if possible. Our current living situation makes building the box in our garage a little difficult as our MOG occupies 90% of the space

We'd thought about hiring a local boat maker to do it, but thought to check here first. Westys build, the super camper and the Turtle V are all emblematic of what we had in mind. We may just forge ahead in our tight confines but starting with a shell would be wonderful.

All thoughts appreciated!

Thanks,

Scott and Heather



Sent from my iPhone using Tapatalk

 

[peneumbra]

One possibility is having something built by one of the firms that makes custom truck sleepers (ICT, Double Eagle, etc). They could probably construct anything you specc'ed out, BUT they tend to be pricey...

 

[quickfarms]

I heard that 3M bought nidacore and then stopped making it. I would like to find a supplier for the nidacore or similar foam cored panels. All of the box builders that I know of use a steel or aluminum frame and skin it with various materials.

 

[LukeH]

This often pops up and I'm always surprised that there are so few options on your side of the pond. Surely there are body shops that specialise in refrigerated delivery box vans? How does the ice cream get to all those Miami beachfront bars we see in the movies? You have the ideal situation because you don't have to worry about the subframe; you already have one.
I've done something else: I recovered an undamaged length of a semi trailer that jacknifed. I have enough high quality insulated panels to make up my box as I want. A friend ordered new panels to assemble himself, and his box now costs ten times more than mine...
Surely you can find a wreckers yard with a refrigerated semi from which you can cut the panels you need. They'll be as tough as the nida, if not more.

 

[dlh62c]

....wondering if there are any independent builders making Nida-core style composite, shells only (we'd like to layout and outfit the interior ourselves). Basically folks building high strength shells you can lay out how you'd like. Trying to stay well south of 50k for the shell if possible.

You might try to find a company near you, like Craftsmen Industries, that builds custom mobile displays, event and concession trailers. They should be able to help and offer suggestions.

Concession Trailers
Craftsmen Industries
Craftsmen Industries

TruckConversion.net is a great source of information for converting a cargo truck body into a mobile living space.

 

[Jfet]

Are you stuck on nidacore? Maybe for weight reasons?

We went with a steel frame and aluminum skin and it has worked fairly well and wasn't *too* expensive or very heavy. (easy to weld steel and the joints are stronger than aluminum welds). Not nearly as heavy as you might think because we sized the steel for what we thought each structure element needed. The aluminum skin is bonded to the steel with Sikaflex 252 (with nylon spacers) and won't come off without a small nuclear explosion. Walls are then filled with 2 inches of polyisocyanurate insulation (somewhat fire resistant compared to other foams).

All buildable by someone with no prior welding skills (MIG is so easy!)

 

[mhiscox]

You might want to look at buying a u-haul truck with "close" to the right size box. Remove the box then sell the cab and chassis. I have heard of people doing this and actually getting their box for free (after selling the truck).

An excellent point. I'm not saying that many of us could do what Steve did with the Bullet-XV, but check out the build information here: http://bulletxv.wordpress.com/2009/03/02/the-donor-vehicle/,

and also here: http://www.expeditionportal.com/forum/threads/34294

 

[Maninga]

Have a chat with Marc from XPCamper. I'm tossing up my options after deal for used camper fell through, was talking to him about some new panel construction for making custom campers under way at the moment.

I'm also on the hunt for a composite material, using Yves (westyss) build as my inspiration.

 

[S2DM]

Jfet, really nice work on that box man. Looks great!

Are you stuck on nidacore? Maybe for weight reasons?

We went with a steel frame and aluminum skin and it has worked fairly well and wasn't *too* expensive or very heavy. (easy to weld steel and the joints are stronger than aluminum welds). Not nearly as heavy as you might think because we sized the steel for what we thought each structure element needed. The aluminum skin is bonded to the steel with Sikaflex 252 (with nylon spacers) and won't come off without a small nuclear explosion. Walls are then filled with 2 inches of polyisocyanurate insulation (somewhat fire resistant compared to other foams).

All buildable by someone with no prior welding skills (MIG is so easy!)

View attachment 210311View attachment 210309View attachment 210310View attachment 210308

 

[daniel ruops]

Ebert Composites, Chula Vista Ca.

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[TD="width: 926"]for your consideration

TRANSONITE™ Sandwich Panels

---

TRANSONITE is the end result from many years of R&D, first conceived from a grant through the National Institute for Science and Technology (NIST), Advanced Technology Program (ATP).

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[TD]TRANSONITE Specifications
Advanced proprietary FRP pultruded sandwich panels utilizing 3-dimensional skin connecting fibers.

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[TH="class: style5"]Parameter[/TH]
[TH="class: style5"]Minimum[/TH]
[TH="class: style5"]Maximum[/TH]
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[TH="class: style5"]Width[/TH]
[TD]

6 inches​

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102 inches​

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[TH="class: style5"]Length[/TH]
[TD]

1 inch​

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[TD]

UNLIMITED​

[/TD]
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[TH="class: style2"]Facing Thickness[/TH]
[TD]

0.1 inches​

[/TD]
[TD]

0.5 inches​

[/TD]
[/TR]
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[TH="class: style5"]Sandwich Thickness[/TH]
[TD]

0.5 inches​

[/TD]
[TD]

4 inches​

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[TH="class: style5"]3D Fiber Density[/TH]
[TD]

0 per sq inch​

[/TD]
[TD]

16 per square inch​

[/TD]
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TRANSONITE is a customized product designed for the end use. The core material may very (foam, balsa, phenolic, etc.), and a wide range of fibers, fabrics, and resins can be utilized for the composite skin. The overall thickness can vary up to 4 inches. Individual skin thickness may vary, and the density of 3-D fibers is adjustable. This creates the ideal sandwich panel that can meet all strength, weight, and cost demands- regardless the application.​

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[TD]Benefits
The 3-D through-thickness fibers in TRANSONITE provide greater durability than conventional sandwich panels. Delamination, a common problem in conventional sandwich materials, is virtually eliminated with the 3-D reinforcements that tie the face sheets together. As well, TRANSONITE is one of the only panel products available which can be produced at any length, and width up to 8.5 feet. This provides large clean surfaces with no edges or seams.
TRANSONITE can be manufactured using a wide variety of core materials, reinforcements, fabrics, and resins.
TRANSONITE Delivers:

• Extremely High Strength
• Very Lightweight
• Corrosion Resistance
• Extreme Durability
• Large Panel Size
• Acoustic Dampening
• Insulative Properties
• High Volume Production
• Ability to be virtually "fire-proof"
• Low Cost

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[TD]Applications
TRANSONITE is ideal for many different applications due to the wide array of benefits it can provide. A few of the applicable industries are listed below:
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• Bar Stock
• Aerospace
• Air Cargo Containers
• Automotive
• Furniture
• Lumber Replacement
• Recreational Equipment

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• Ballistic Panels
• Truck Trailers
• Marine
• Air Matting
• Rail Cars
• Bridge Decks
• Industrial Mats

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[TD]TRANSONITE Solid Plate
TRANSONITE Bar Stock is as strong as steel yet lighter. It can be pultruded up to 1 inch think, up to 8 feet wide, and at any length required.
Bar Stock made with the TRANSONITE process, contains structural fibers spanning from every end-to-end. This solid composite is ideal for machining small components, as it will never delaminate.
This Bar Stock is ideal for use in corrosive and marine industries, and can easily be fabricated with CNC equipment using diamond tools or water jet. Additionally, because it has 3-D fibers, machined components hold together.[/TD]
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[TD]Licensing Opportunities
Currently TRANSONITE materials are manufactured by Ebert Composites and by Martin Marietta Composites in North Carolina, under a license agreement. The TRANSONITE trademark is registered and also licensed to Martin Marietta Composites.[/TD]
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[TD]TRANSONITE® is a registered trademark and is manufactured under one or more of the following U.S. Patents: #7,056,576, #7,217,453, #7,785,693, #7,846,528, #7,387,147, #6,676,785, #6,645,333, #7,105,071, and #8,002,919.[/TD]
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[quickfarms]

Are you stuck on nidacore? Maybe for weight reasons?

We went with a steel frame and aluminum skin and it has worked fairly well and wasn't *too* expensive or very heavy. (easy to weld steel and the joints are stronger than aluminum welds). Not nearly as heavy as you might think because we sized the steel for what we thought each structure element needed. The aluminum skin is bonded to the steel with Sikaflex 252 (with nylon spacers) and won't come off without a small nuclear explosion. Walls are then filled with 2 inches of polyisocyanurate insulation (somewhat fire resistant compared to other foams).

All buildable by someone with no prior welding skills (MIG is so easy!)

View attachment 210311View attachment 210309View attachment 210310View attachment 210308

Do you have a build thread?

Is the insulation bonded to the skin?

 

[Jfet]

Do you have a build thread?

Is the insulation bonded to the skin?

No, insulation is not bonded to the skin, it is R13 2" polyisocyanurate fire resistant insulation. The spray stuff does not have as high a R factor, is quite hard to get sprayed to a even 2", and is quite flammable. The skin is bonded to the steel frame though, and with the insulation as a backing, makes for a quite solid sounding side when you rap on it.

I have a little build info on expeditionportal: http://www.expeditionportal.com/forum/threads/94236-bought-our-truck-starting-a-huge-new-build!

And a much more detailed build thread on rv.net: http://www.rv.net/forum/index.cfm/fuseaction/thread/tid/26735683/srt/pa/pging/1/page/1

 

[mog]

TRANSONITE is the end result from many years of R&D, first conceived from a grant through the National Institute for Science and Technology (NIST), Advanced Technology Program (ATP).

John's Uber-Fuso's camper is build with Transonite (http://www.expeditionportal.com/forum/threads/89454-My-Fuso-FM260-is-converging?highlight=my+fuso).
It is a pretty awesome material. He speaks very highly of it and in person the material looks great and would seems to be a perfect building material. There were factory extrusions available for all the corners/joints.