Rowerwet thanks for the info on pictures but maybe I’m all set on this, the post from toyhauler was the one I was looking for.
I’m leaning towards using a panel, 1” foam sandwiched between 1/8 luan as the floor for my build, and then attaching the walls to that. I’m planning on using 2” foam for the rest, walls, roof and hatch. I’m thinking it might be easier to get the panel flat and then build down on the edges to get it tight to the roof profile. Also I will need to either hinge the back, over the rear sitting area, and the area over the access hole in the front. Most of the curve in the vehicle roof is on the edges and in the front, with most of the front roof curve within the skylight hole, where I won’t really need a floor. I’m planning on banding the edges with 1 by pine to protect them. Also since I’m working with 4x8 sheets for the side wall, and nominally a 2’ height I’m less likely to finding myself needing more than a 2’ piece of foam, and needing another sheet. I’m thinking that this will add about 15 lbs to the build, I’d rather not but I’m thinking it might work out better. I think trying to sculpt a 2” piece to lay against the roof bottom would be a big waste of time, and shaping the bottom of the side walls, could result in me being a little short.
It occurred to me that where the wall edges meet the floor I could add a piece of say 3/8” ply that was about 3” higher than the inside of the floor and then rout out the bottom 3” of the foam, making a stronger connection? This is added weight, so maybe it’s not necessary?
It seems that everyone uses some wood in the roof, are these structural? Since interior height is important to me, has anyone routed these into the foam, say ¾”, would this add to or decrease the strength? It would give a larger gluing area.
As far as the shape what can I do to increase the aerodynamics, except build a tear or get a van?
I’ll try to lower the angle on the front, it’s 45 on the mock up, but bringing it to the rear does cause height problems getting into it from the front. Also most of the tear’s slope down from the high point. How much does all this matter, what can I gain and lose?
The front skylight will be a second windshield, I thought of using the glass from the hatch but it’s too big. Glass is heavy, and I should use safety glass, or some kind of plastic. I’m worried about plastic getting scratched up from the road, more so then on the side or rear. Any suggestions?
I’ll try to get the mock up, cut and covered with plastic or tarps,(wont this look classic) and take it up and down the road to see how it handles, this will be at the end of next week. If I move forward I will pick up the materials the following week and get going.
Thanks again Mike
Maybe downsized a bit ... But what you really need is a dedicated Expedition vehicle ... Easy to do that on an old Van ... We had an old 60’s Econoline , that we jacked up and customized for going camping at the beach ... Dropped in a “massaged” Ford 300 straight six , headers, special tires ... We went and camped everywhere in that one ...
My daughter is running around Africa.......again, they are in one of those. Not what I want.
I have to relearn everything, every time I guess 
Going for a hike, I'm up before dawn my favorite time of day, the birds are coming back and no bugs yet.
