Project 1x1

[benjamin]

This guy used frp and fiberglassed the seams.
Scroll down.............................
http://www.snapdrive.net/files/50067...%20project.pdf

[3jarrells]

This stuff intrigues me. I work in a sign shop we use alot of aluminum, but seem to be transitioning to this for road signs. It has a plastic core with al skins on either side. I think it would make a great sheating, we get it in 4'x8' pieces...

http://www.reedconstructiondata.com/...posite-panels/

[toyrunner95]

Well things are slowly comming into fluition. Waiting on funding. I want 1k cash money just to see how far I can go on that.

I think the FRP will work well on the outside. I plan on Using corner pieces on the front at least and some extra strips of frp or fiberglass cloth to seal the corners. This is sandable and easily placed at any angle. I will also seal the hell out of the inside. Two or three times if necessary. You can never have enough silicone.

The insulation I figure I will use chunks of foam board. Easy to find at Home Depot and other hardware stores, plus it is super light. The interior I havent decided if I want wood, 1/4in plywood to cover everything, or more FRP. It depends on the price. Mounting things like lights to wood is simple.

Crap! I forgot about doors and windows. Thats where I am going to loose money.
Well for money sake I will see if I can't build a shell for under 1k I guess.

[benjamin]

Find an rv salvage yard in your area for windows and doors.

[allochris]

or make your own w/ plexiglass scrap!

[toyrunner95]

well the project is kinda comming together. I bought a ladder/lumber rack today for 200 bucks. Total steal! This type goes for 1000 to 1500 brand new and its in pretty good condition. It came off almost the exact same truck to it fits like a glove.

The plan is to make like a can back system for it first for summer camping, then as the seasons change and i get used to using it i will wall it in and hard side it into a camper later. but so far so good in under 1000 bucks!

[Ironduff]

Just an FYI for future reference... Aluminum doesn't really take any special tools to cut.... I've cut 1/4" plate with a carbide tipped blade in a skilsaw. Don't recall the alloy and temper, but it was not soft by any means. Yeah, that tool does limit you to straight lines, but it works just fine. I suspect that a saber saw might work, too, for short curves, but I dunno what blade would give reasonable life.

If I was cutting really thin gages with either, I'd probably support the cut area on a sacrifical piece of plywood. Eye protection is a must. The skil saw throws chips like a muthafadder, and they're hot, hot, hot.....

Jim H.

[toyrunner95]

Cutting the aluminium isnt the problem. its weldign it back together. i dunno how to do that.

[Herbie]

Cutting the aluminium isnt the problem. its weldign it back together. i dunno how to do that.

Just overlap and rivet.

For lightweight trailer ideas, checkout these guys:
http://www.compactcampingconcepts.com/

The founder is a member here and I bought the book when I was considering an ultralight offroad trailer to tow behind my Subaru. In the end I had to go another way to have enough creature comforts to keep the wife happy, but this is a strong concept for a "towable-by-anything" trailer.

[HMalice]

I was planning on building a cabover shell for my truck, bed frame angle iron is typically cheap/free and pretty strong.