FiberCorr?

[woytovich]

Is anyone using this stuff for an interior or exterior build material?http://tinyurl.com/colsvvl

[jonw]

I used this stuff as a "headboard" that I got from HD in 3x6 ft sheets for about $10 each.

http://www.homedepot.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10051&productId=202489118&langId=-1&catalogId=10053&MERCH=REC-_-product-1-_-202038094-_-202489118-_-N&locStoreNum=2607

It's very light and easily coutours curves so it would make a nice interior ceiling material. It's much lighter than what you are looking at though.

I'm considering using AlumaCorr for exterior walls on my next build which is very similar to what you are looking at but which is coated on both sides by thin aluminum. Google it...

[Treeview]

AlumaCorr looks interesting.

Read this:

AlumaCorr panels are ideal for exterior applications with a life expectancy of approximately 10 years.

From:

http://www.alumapanel.com/howto_detail.cfm?id=129

[woytovich]

This same company make an aluminum sheathed product... it is called Endurex

http://www.nudo.com/Exterior-Panels/Designed-Performance/Endurex300.aspx

[jonw]

This same company make an aluminum sheathed product... it is called Endurex

http://www.nudo.com/Exterior-Panels/Designed-Performance/Endurex300.aspx

Checking the tech sheets and warranty info on the Nudo website, Endurex has thicker aluminum and FRP skins that can be ordered in different thicknesses, and the material the skins are laminated to can vary as well (including the same corrugated scrim used for AlumaCorr). I'd expect it to be heavier and more expensive than AlumaCorr, but it would probably be acceptable for a teardrop. You'll have to determine the strength, weight and cost tradeoffs.

Endurex has a 10yr warranty and AlumaCorr has a 5yr warranty. Both are for manufacturing defects, not for life of product.

Interesting stuff..

[jonw]

AlumaCorr looks interesting.

Read this:

AlumaCorr panels are ideal for exterior applications with a life expectancy of approximately 10 years.

Disclaimer: I am not associated with Nudo in any way and am not pushing any of their products.

AlumaCorr is made for use in road signs that are exposed to the elements year round. Unless you are using your teardrop year round and/or leaving it exposed to the elements in the winter I'd expect it to last 2-3 times longer than that.

In my case a 20-30 year life expectancy for an ultralight teardrop is a good tradeoff, especially if it's designed to be not too much work to install new exterior panels to re-clad it then. Also, at my age (60) I'll probably be dead in 20-30 years...

[mikeschn]

Where would you buy this Endurex?

Home Depot? Lowes?

Mike...

[jonw]

Where would you buy this Endurex?

Home Depot? Lowes?

Mike...

It seems to be sold by certain building supply companies. I called Nudo, spoke with the New England regional manager and he gave me the name and number of the company that sells it in my area. Turned out it is a well known supplier to the construction industry.

I'm going to call them next week to get prices, availability, etc. I also requested a sample on the Nudo website which they are sending to me. You can do the same...

I've been looking for a lightweight but strong exterior wall material that can be mounted to a thin, mostly vertical frame to build a WaWa-like lightweight popup. So far this is the best I've found and the fact that it comes pre-finished in various colors is a bonus (ie. less finishing work required).

[woytovich]

I have ordered some samples from FiberCorr and Endurex. I will post up here once I have them in hand. HD sells FiberCorr.

My intent for this by the way is in constructing a topper for a military M416 trailer. I am thinking of a hi/lo arrangement that can be roughly 24" tall during travel and raised to 48-ish during camping. I would install screened windows and a roof vent.

Mark

[mikeschn]

Does anyone have an idea how much a 4x8 sheet would cost?

Mike...

[jonw]

Does anyone have an idea how much a 4x8 sheet would cost?

Mike...

Mike - I'll post the price of AlumaCorr next week after I talk with the local distributor.

[woytovich]

$485 for 5 4x8 sheets of fibercorr at hd

[Trackstriper]

Here's a reference for price and availability of types of products. These guys are in my local Atlanta area and supply local sign shops. I'm an occasional customer, that's all...disclaimer. There should be similar suppliers in major cities to handle the local supply needs. Your local sign maker could probably arrange to get some product for you.

http://www.alumapanel.com/subcategories.cfm?step=1&lines_ID=289

Regarding the Endurex 300. If one goes to the web page woytovich posted and clicks the "stabilizer" button near the "1, 2, 3" diagram you will note a variety of possible core materials. Whether or not Endurex is a little different from other Nudo products may be minor. Companies like Nudo will laminate all kinds of stuff for you if you want a big batch. For our purposes we need to find the "over the counter" product. Economics will favor such a product too. Other manufacturers make competitive products, this is just the brand my local guy carries.

Back to Endurex cores....

"Hardboard" core: Nudo makes a composite with aluminum skins and a plywood core called Nu-Alum. It's a nice product but fairly heavy. I've hefted a 1/2"4x8 sheet and it's got some weight to it...like 3/4" plywood.

"Composite" core: Nudo also makes 3mm and 6mm "Polymetal" which is aluminum bonded to a solid polyethylene sheet. 3mm is actually heavier than the 10mm Aluma-Corr and is much less stiff, although an interesting product. I've got a dozen sheets sitting in the garage that I will be putting to use.

"Corrugated" core: Nudo makes "Aluma-Corr" in 5mm and 10mm thickness, corrugated polypropylene core. The 5mm is not nearly as stiff as the 10mm. A 4x8 sheet of 10mm weighs something like 22#, about the same as 1/4"plywood, but quite stiff. If you take a quick glance at Nudo's page http://www.nudo.com/Sign-Panels/Designed-Performance/AlumaCorr.aspx you'll see a vestige of a reference to Endurex 300. Probably the same stuff. Also note on AlumaPanel's site that the sheets are available larger than 4'x8"......4'x10', 4'x12', 5'x10'.

"Cement Board" & "Gypsum" cores......LOL.

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If I were to build a light TD for myself I'd be looking very strongly at Aluma-Corr. My local sign shop supplier has nearly all the materials for the body shell:

Floor: 1/2" prefinished MDO. (let them do all the coating work)

Sidewalls: 10mm Aluma-Corr white. Have the local sign shop cut two identical pieces on a CNC router, cut the doors at the same time. The corrugations would run horizontally. A few 1"x1" vertical aluminum tube stiffeners would be bonded to the interior of the walls with foam sign tape, poor man's VHB. http://www.alumapanel.com/view_product.cfm?step=1&lines_ID=307&name=Alu-%20Tape%20Double%20Sided%20Foam%20Tape

Roof "rafters" 1" aluminum tubing. Roof material would be a single piece .040 white aluminum sheet.

Shelves and cabinets can be made of Aluma-Corr, use 1" tube (or aluminum angle) and foam tape to join perpendicular panels. A trim cap is available to close off the exposed edge of the corrugations.

Glue 1" pink insulation board between wall studs and between roof rafters and cover inside surfaces with nice cloth, perhaps.

This method would solve a lot of the problems associated with trying to stick aluminum onto plywood after a wood structure is built. It is prefinished and durable. Very light. All the aluminum will expand and contract at about the same rate and solve some problems of dissimilar metals in the upper shell. Also, there's no formaldehyde to deal with, a personal issue for me.

Some food for thought.

[GPW]

This might be a good glue for skins .... sticks to foam , wood, and metal ... http://www.alumapanel.com/view_product. ... e%20Primer

If it has a sign lifetime of ten years , seems it should last forever protected in a garage or shed ...

[Treeview]

A compilation of various sign boards:

http://www.alumapanel.com/subcategories ... 353&step=1