Everlanders Build - F550 Composite Overlander

Next, we installed the Honeycomb Composite panels, I can not recommend any manufactures, sorry.

All mating surfaces were scuffed, primed with Sika 206 and then bonded using SikaFlex 252.

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We used small strips of a stiff rubber gasket material with 2 sided adhesive to act as a 1mm spacer so that when the butterfly rivets were installed it did not press all the adhesive out. Here Kara is poping rivets like a mad person...

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The rivets are not needed for the structure, but they are the perfect clamp to hold the aluminum tight to the panels as the Sika cures.

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I installed the absolute brightest, most densely populated LED strips inside of 45-degree aluminum extrusions with nice diffusers so I could see what I was doing as I added the last of the panels.

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The videos for this stage is here:



Are you unhappy with your panel supplier? Knowing who can supply the clad honeycomb panels would be a big help on my project.
 

Txkronik

New member
Yah would think so I am starting the research phase and need to find good vendors.

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Txkronik

New member
How do you mount cabinets to the composite walls .

Really curious about the interior finish out.



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ersatzknarf

lost, but making time
Great thread ! Have been subscribed on YT and liking the videos for some time ! Thank you very much for sharing ! You folks have really done something wonderful :D
 

amccunn

New member
Thanks! I drew a bulk of the CAD myself, although I had help from several ME friends who work in the industry. I did get ahold of the CAD model from Ford, but it was 8 gigs and when opened it brought my high-end system to it's knees. So I just used the body panels you can see there and omitted most everything else. But as you can see, the Ford Model is very detailed:

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What CAD program do you use?

How did you get the file form Ford?
 

beardinc

Observer
Would be cool to see a video on the air conditioner. Real world usage/draw on battery bank would be helpful as I know AC is a big issue for alot of folks.

Also how is the unit holding up being located outside and uncovered? Also how's it taking the abuse from off-road/bumpy road conditions.
 
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