take it easy on me I'm no craftsman but I'm trying my best.So it started with a template I cut out of 5x10 4mm okoume. I scaled up a drawing my girlfriend made until it was large enough to plot some x,y points on the plywood. I basically followed the Steve Frederick approach here...
My walls are solid 3/4" cut from 5x10 birch plywood, I used a jigsaw to get close then a trim router bit to clean it up. The door openings were cut out to fit challenger doors. I'm not at the shop but they were the largest I could buy 30×36 maybe? I should really know that off hand. I routed 3/8 of an inch out of my wall to help support the headliner and then along the bottom to give the wall a lip to sit on top the floor... (picture doesn't show the bottom of wall routed for floor lip)
The floor is 1/4" okoume skin with 1" red grandis used for framing. Im lucky to live around the corner from a marine supply store so thats where I've been getting my hands on the okoume.
The 1" inch frame is filled with xps foam that I glued to the skin. I used pl300 to glue the foam to the skin and really wasn't happy with the result. It peeled up in a bunch of spots and I salvaged it with titebond as best I could. I think this may be because I spread out the glue as I went and a lot of it dried before I was able to weigh it down fully. Luckily this is the bottom skin and it will be thoroughly bolted down to the frame. I'm hoping to get some more suggestions before tackling the top skin
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I've just finished fibreglassing the floor and once it cures I'll paint it and bolt it down to the frame.
Frame is an aluminum 5x9 box I had welded up by a local trailer manufacturer. It has a 2200 lb. Dexter axle. Wheels will be swapped out for 15" before I'm done.
Next I'll be glassing the walls on the bench...
I'll keep posting as I go
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