Polystyrene FRP Stress Skin Teardrop

[KennethW]

Just brain storming a ideal.Building a teardrop without any wood(wood drys out or rots) or aluminum. Using just 1" polystyrene and fiber reinforced plastic. Making stress skin panels with the polystyrene and the FRP by Gluing and vacuum bagging. Need to find a good glue that is roll-able and waterproof. Thinking polyurethane varnish or Titebond II Premium with polyurethane chalk on the joints. The step in construction might be
1# Glue and bag the floor and side panels
2# Cut the inside profile on the inside or the wall panels leaving the outside FRP run wild. Making a step for the floor and the roof to set in. Floor step could be formed in step 1#.
3# Glue the walls on to the floor.
4# lay plastic sheet over the walls to make the inside of roof vacuum bag.
5# Lay the ceiling FRP over the walls in the step in the walls, glue, put in the sloted (to bend) polystyrene,glue, FRP. Lay the plastic sheet over the top. tape and vacuum with ratchet straps holding it to the walls.
6# Remove the bag and glue down the roof with the polyurethane chalk.
7# Cut the doors and hatch off.
8# Glue FRP strips to the cut edges.
9# Mount the door and hatch with glue and bolt that go thru. The inside would be drill bigger for a spacer tube with a fender washer on the inside.
What glue would be best? Any thoughts? Am I crazy or is this a cool ideal.
Like I said at the top of the post Just brain storming.

[angib]

Sounds good in theory - and nearly impossible in practice.

As you've worked out the trick is how you make the corner joints and you seem to assume that sticking the foam together is enough - but I don't think it is, as you need to stick the FRP skins together (unless you use structural foam costing $00s). So your nearly impossible joints (you seem to expect to cut them all with great precision, but without the mating component present) then become really impossible.

[KennethW]

Thanks for your comment. It always helps to get some input when reinventing.
What it I cut the foam a bit long. Then use a old clothes iron to create a hard surface to glue to? The shape of the a teardrop makes the need for a really strong joint unnecessary ,but One doesn't want it failing apart.