DIY Composite Flatbed Camper Build

#16
I made the bathroom walls prior to the roof going on. This was easier bonding than with the roof already in place.
Any thing that can be bonded to the inside of the box will increase overall strength.
I used 1/2" foam from home depot. After lamination, a 3/4" aluminum c channel also from home depot or lowe's was used around the edges. I used sika for this as well as bonding to the camper interior.
IMG_20170624_133450760.jpg
IMG_20170704_141323757.jpg
IMG_20170704_141336699.jpg
 
Last edited:
#17
IMG_20170721_162602880.jpg
IMG_20170721_162602880.jpg
IMG_20170721_162611781_BURST000_COVER_TOP.jpg

For the odd angles/joints I took a small stick of aluminum and bent it over the corners where needed, then took to a metal shop where they cut and bent the aluminum to my specs.
It fit perfectly. This too was needed for the inside.
IMG_20170819_093158081.jpg
IMG_20170819_093135598.jpg
IMG_20170819_093149526.jpg
 
#18
This looks great. A while back I was considering a sandwich panel for the trailer I was building but was unsure if it would be strong enough. I had originally plans on 1 1/2" ridged foam sandwiched by 2- 1/16 thick sheets of aluminum.
Seeing this thread I may have to source out some fiberglass skin...
 

calicamper

Expedition Leader
#20
Really nice. One of my sailing buddies Antrim Composits. Number one thing builders can do to increase composit strength is high quality Resin. Sounds like you figured that part out pretty quick. Looks great!
 
#22
Thanks for the comments.
One thing to note, with the ability to make your own panels, the applications are numerous.

Here are some more pics during assembly;

IMG_20170824_124426502.jpg
IMG_20170915_140638840.jpg

Like I said, never done this before. Angles do not always
come together perfectly, but I have found there is a lot of room
for forgiveness. Before and after some aluminum touch up:)

IMG_20170915_143738221.jpg
IMG_20170915_143743572_HDR.jpg
 
Last edited:
#23
Made jack mounting brackets out of aluminum.
Since these points will take the most stress when lifting, I had planned on bolting
all the way through to the inside. However, this did not work out since I used a smaller
L bracket "3inch" instead of 4. I needed a right angle to fit snug against the 4 inch exterior.
They only make 3 inch. Had I gone to 4, the inner angle would curve and not fit.
I ended up attaching by using the Sika and stainless lag bolts to attach the brackets
to the exterior L channel.
I had my concerns, but after lifting and mounting the camper, I felt better.
IMG_20171004_102500163.jpg
IMG_20171004_102511254_BURST000_COVER_TOP.jpg
IMG_20171004_102520453_HDR.jpg
IMG_20171103_095102258_HDR.jpg
IMG_20171103_095121279_HDR.jpg
 
#25
First step was to locate the fiberglass skin. This actually took longer than I thought it would, but found a manufacturer practically in my own back yard. http://www.vetroresina.com/?lang=us
Love your build! I considered something similar, but ended up going with hand layup on 20 psi Foamular, so I could do curved surfaces. I used the cheap foam because I couldn't find anyone willing to get the 60 psi foam locally, and shipping would have doubled the cost.

What are the specs for the skins you are using? Thickness, weight? FG, polyester resin with gelcoat?
 
#26
Love your build! I considered something similar, but ended up going with hand layup on 20 psi Foamular, so I could do curved surfaces. I used the cheap foam because I couldn't find anyone willing to get the 60 psi foam locally, and shipping would have doubled the cost.

What are the specs for the skins you are using? Thickness, weight? FG, polyester resin with gelcoat?
FRP.jpg
 
#28
Thanks, looks like good stuff and the price seems very reasonable.
Yeah, learned a lot about panels over the last year. Not too many manufacturer's want to deal with the little guy and the one that does ships it in from China.
Vetroresina had no problem selling product to me. Very happy with the results. Some times you just have to do it yourself :)