Thrifty Alternatives ..Building Foam Campers

[atahoekid]

Has anyone thought of using the wood from pallets? I thought I might be able to make my spars from the larger pieces. Might have to glue a few together to make it my planned 5' width. Lots of time and no money?

My problem with pallets is that the wood used in them is typically crap. I'd be concerned with structural failure. I went with 1/2" birch plywood. A bit pricier but solid. I agree with GPW. Though I didn't skimp much during my build the one place I used the best materials I could afford was the floor. I also probably overbuilt it too. Just my 2 cents

[atahoekid]

There seem to be a lot of ideas about how a foamie should be built , but when it comes to the interior , we always resort to 2X4s and thick plywood for the shelves ... Consider this , how about a 2” thick foam shelf, FDT (fiberglass drywall tape ) run full spam on top and bottom , then skinned and painted ... Very Light and you could probably dance on it ...

I was thinking of doing that for my kitchen. My plan would be to put a couple of supports underneath, like spars. Perhaps overkill as what you are describing sounds strong enough.

I thought of foam shelves but my issue was the thickness of the foam really eats up useable space. I essentially made boxes of 1/2" ply with face frames. The walls and face frame keep the boxes from racking, the face frame also helps with support. Definitely lots heavier than foam but strong sturdy shelves. To each their own. As long as it works and makes you happy!!!

[atahoekid]

Hey GPW & Jack B!, Thanks for the artistic hints. After I clean up some things on the Road Foamie ( a couple of redos, a couple of improvements and a few items to be completed, I may think about a different paint job. This one actually does its job (deflecting the elements) well. Just would like something eye popping!!

[GPW]

Mel, I think it looks Pretty darn GOOD right now !!!

[Jack B.]

Yup, it looks fine. Don't take this as an insult but it looks store bought. If it's as nice on the inside, do a new build and sell this one to pay for the version 2.0. If you're like most of us there's a lot you would do differently the second time around anyway.

For the floor on my clam shell coffin sleeper I used 3/8" plywood for the floor and 1/4" luan for the top and sides. All framed with 1"X2" with a liberal application of varnish and paint all around. Not worried about failure as the trailer frame offers excellent support, I've noticed no flexing at all. Pulled it on a 600 mile trip in the rain with my '79 Suzuki GS850 with nary a problem. Would go with 1/2" for the floor if I was going to do a bigger, stand-up, walk around unit. Two cents ain't worth what it once was, but there's mine.

Jack

[GPW]

Yet another “stress test” ..... just had one HE(double hockey sticks ) of a HAIL storm go over us ... Quarter size Hail and Lots of it .... Once passed, I ran outside with the flashlight to check the Foamie .... No problems ... not even any dents ... Tough Stuff Canvas over foam !!!... although this testing bit is becoming a bit “scary” ...

[Wolffarmer]

Yet another “stress test” ..... just had one HE(double hockey sticks ) of a HAIL storm go over us ... Quarter size Hail and Lots of it .... Once passed, I ran outside with the flashlight to check the Foamie .... No problems ... not even any dents ... Tough Stuff Canvas over foam !!!... although this testing bit is becoming a bit “scary” ...

You need a contract with NASA

[GPW]

Yeah huh? Put a Foamie on the moon by June ....

[wagondude]

Yet another “stress test” ..... just had one HE(double hockey sticks ) of a HAIL storm go over us ... Quarter size Hail and Lots of it .... Once passed, I ran outside with the flashlight to check the Foamie .... No problems ... not even any dents ... Tough Stuff Canvas over foam !!!... although this testing bit is becoming a bit “scary” ...

If you hurry, you can bring it up here for the "snow load test". We are supposed to get another 10-12 inches on top of the 10 we got last Thursday. Got my coffee and chickory ready to go.

[GPW]

WD, I’ll be right up !!! Leave a light on !!!

[GPW]

Whoa !!! Upon closer examination of the Foamie (stopped raining, could go outside in the light ) , looking from a certain angle saw hundreds of slight pock marks on the top .. Only one particularly Large one tore the canvas on the edge (slightly , NBD) ... probably a good day in the Sun will pop most of those back out ... That’s if the sun comes back out .... raining again now and expecting more Hail any minute ... what the ...?
No worries , nothing to absorb water , nothing to Rot ... All’s well !!!

Ps. the hail last night , described by one observer on the local news , as of “biblical" intensity, damaged many homes and thousands of cars ... in just 15 minutes ... More to come !!! Stay tuned !!!

[Mary C]

So, If I put canvas or newspaper or t shirts or other material with paint or TBII, you think under a mattress that would not be strong enough for the floor?? I know I weigh a lot but............ I thought putting on a piece of ply under the floor was for the Black stuff for protecting for rock damage. Do you think I need 2 pieces? one on top and bottom of the floor?????

Mary C.

[KCStudly]

MaryC, it has been done successfully many ways. We have seen people use ply on top with open foam (sometimes painted or tar) underneath. We've seen foam put inside on top of plywood after the fact, and we've seen sandwich construction.

The denting concern with foam on top is mostly during the construction phase and/or for people who plan to haul gear inside with the mattress folded up or removed (dual purpose use). If you use a couple of layers of canvas and glue/paint and spread any loads out with a mattress you would probably be okay, but consider putting a piece of ply down during construction so you don't have to worry about it. the other side of this argument is... well, since you have the ply there for the construction phase, why not just install it permanently and not ever have to worry about it? the only reason I can think is if you were going for absolute ultra light weight.

I wanted the best of both worlds, light weight, yet durable, so I went with thin 5mm ply both top and bottom. I can press my hand down in the middle of a bay in my floor assembly and see a touch of spring/deflection, so even with that thin ply I do have some concerns about kneeling on it (I'm over 250 lbs). I am sure if I am not careful I could easily poke a step stool leg or temporary prop rod through the skin. So if I am doing anything like that during construction I will lay a temporary section of 1/2 ply down first.

[Mary C]

KC I will take it under advisement , I have been looking for where I saw the reference to it but I can't find it so since I am not there I will have to wait a month. I did order my canvas today. after my son suggested I build it 4 ft wide and not to worry about 5 ft wide for him. I still have time. I will continue to think about it. Oh I have my trailer and all the pieces are here. now to find where someone gave directions on putting it together and what type of bolts to replace and which ones......... I do have a lot to do. Going back to reading.

Mary C.

[Wolffarmer]

KC, You would not need a very thick piece of plywood on top of the foam, 1/8 inch would be more than enough. I would build it first like you want to now and then try it and see, If you need it you can easily add some. then only where they heavy parts of the body is. I doubt if your feet would cause problems.