How would you make these panels ?

[CompoSimmonite]

I'm itching for another camper body that could be mounted either on the back of my Mahindra or 8' x 4' flatbed trailer.
Last time I bought 2 identical fibreglass tops that were off 8' bed pick-up's and intended turning one upside down to use as the lower then bonding them together but then was offered a ready made camper body (Romahome on Honda Acty pick-up). Looking it seems 8' beds have gone out of fashion with the popularity of crew cabs so I'm not going to find another pair of tops for £5 each like last time
With searching for ideas I have come across this which appeals to me -
Teal Tail Feather Camper
http://www.tealinternational.com/TailFeather/index.html

It's a modular shell so I like the idea of being able to dismantle for storage, alter length & height (fixed or pop up roof), be used as free standing "shed", and so on.
This shows how it's constructed -

Individual side panels along the lines of a concrete garage

I'm NOT thinking of replicating this design but rather using a similar type of modular panels for my own idea so it's be adaptable to my needs.

At present I've been (for many years) mentally debating how to make the actual panels. So far I've come up with folded aluminium, fibreglass, aluminium frame with slot in composite infill, heat bent plastic sheet with alloy or welded plastic edges, plywood moulded out of thin sheets that are glued together then vacuum bagged over former.

So how would you folks make such panels ?
I should add this is the main side panels and corners would probably need to be fibreglass anyway - unless somebody has another idea

Merry Xmas.

Paul H

 

[ibrooks]

I'd bet those are double skinned fibreglass - probably with an ally frame or at least members inside them and probably foam filled too.

Quite a bit of faffing around to create the moulds but once you've got them and with some industrial laying up equipment I'd imagine they can be knocked out in no time.

Whether I'd do it that way for a one-off........ probably not. Laying up fibreglass manually is a fairly laborious process - especially on biggish stuff like that. With industrial kit that will spray the ready mixed resin and even the chopped strands it becomes a different matter.

Iain

 

[julianf]

If you look at the DIY overland camper builds (really, dont mistake diy for lack of quality - some of them are like luxuary hotels inside!) then most of them use this stuff that's like cellotex in the middle, with ply faces, then covered in (i think) some sort of plastic...

...but

there are companies who you send the CAD file to, and they do you the sections, all (i think) laser cut. you litterally just stick it togehter then (they use silkaflex)

if you wanted it possible to dismantle, im sure you could fit U section along the seams, and then find some way of bolting with sealing strips.

i dont have any links im afraid, but some googling should sort you out?

 

[Shox Dr]

Most likely to be made with abs vacuum formed panels foam filled.

 

[CompoSimmonite]

I wonder for a mould if I could use folded (stainless ?) steel with detachable (wing bolted) sides and then get a commercial place to spray resin & chopped strand ?
Not too bothered about insulation at present as am just thinking about the very basic structure.
Pity you can't get twin wall polycarbonate sheets, the same as used on conservatory roofs, in solid white or other colours. Looked at if you can spray it but difficult to make it stick without a lot of preparation / special primer so not worth the effort. Twin skinned insulated sheets like caravan manufacturers use are an option but a wee bit on the expensive side, not as tough (the idea would be for use as a covered trailer / van for quad, motorbikes, mobility scooter etc as well as a camper at other times) plus I'd still have to make some sort of outer frame.

With way weather is today better consider any design to also be storm proof

 

[sardine]

Folded aluminium sheet, pop rivet together at the edge flanges, which gives you built in stiff frames, spray foam 25 mm, then 4 mm ply lining. Double glazed windows, solar PV roof, led lights., beer fridge.