doug hodder wrote:Great idea Dave....are you thinking about something like a cold molded process like on a wood boat? I was just thinking about how to make all the compound curves...sides can be bent...roof can be bent....where they match...angular or curved? Doug
Living in Idaho, I am not exposed to a lot of boat building!!
My plan is to make the floor, including the integral tongue box, as a long torsion box. The sides would be made for the curved sides. Compound curves are a trick with wood any time, and with plywood particularly, so I think I'll skip it on this one!
I think I'd make the rough sides out of CDX fir plywood, but remove everything that is not necessary for strength and backing. That panel would be bolted to the base torsion box. The 1/8 skin would go on the inside first, then the form the roof in place, probably 1 1/4 thick, total.
Any open space in the sides or top would be insulated. I remember someone being adamant that the floor should NEVER be insulated, and that makes some sense. Besides, there is a 4 or 5" foam mattress to do a LOT of insulating.
The torsion box base would be pointed in the front, so the actual wood tongue would be less than 12" long -- and wood. The tongue box would form a triangle back to the top of the front of the tear, making that tongue extension strong. There would be a solid section in the torsion box floor to support the axle, and the tongue extension.
I think I'd rough in the cabinets in the inside before putting the final outskin in place.
BTW, nearly everything would be made from 1/8 plywood, with the box grids of Western Red Alder.
The rest is rouge and lipstick as they say.
dave