Thrifty Alternatives ..Building Foam Campers

[rowerwet]

don't forget pre-skinning the outside of the curve, since the fabric is in tension and can't break, the foam compresses, it was shown more than once in this monster thread.

[jae]

I couldn't find any info after a quick forum search, so I figured I'd stick this here and see if any of you guys have heard of it, or know if it'd be worth trying. Just a tad cheaper than the pink stuff here locally, and at 1/2" thick it's still rated for structural use. This tells me that it might be a bit heavier than standard foam, but if you could get the strength of 2" thick pink (or blue, or green, etc) out of a 1/2" sheet it might be worth it.

http://www.homedepot.com/p/Unbranded-Qu ... /202089176

I took a look at some of this stuff in person, and I would NOT even bother trying it. Looks like it's just treated particle board. REALLY heavy stuff, and every piece they had on the shelf was disintegrating around the edges.

Now I did get a look at the expanded foam sheets in person for the first time, and I think I'm sold. I happened to see a 25% off coupon for HF today, AND I've still got $100 in gift cards from Christmas, so for about $30 out of pocket I'll have a base to start on my micro foam build.

[GPW]

J’, That’s good to know ... Thanks !!!

[GPW]

We’ve been looking around for a 2” X 2” (or similar) PVC square tubing that may replace any wood framing members on a Foamie ... Less wood , less chance of problems ... But then we saw PVC Channel ... which if we could get the right size , the 2” foam would easily slip inside allowing that to become part of the structure rather than being merely glued on... And you could easily mitre it to form door frames and reversed , door casings ... Windows too ... It all seems pretty simple , depending on if we can find the right size channel ... Still looking ....

[GPW]

Like this :

[Hardryder56]

I wonder if PVC fence pieces would be of the correct size? Also check out the TrailTop thread that Jeff has going, he has designed and made proof of concept fiberglass pieces that can be used to build any number of shapes and he also has a rear hatch rib set up that makes building a Tear Drop hatch a breeze. Molded fiberglass part plus foam would be the best of all worlds.
Hope this link works: viewtopic.php?f=2&t=58690
Tom

[GPW]

Moulded fiberglass parts would be really Terrific for Foamies , just door and window frames is all that’s needed really Maybe just a length of correct fitting fiberglass moulding that could be cut to fit and glued into place ... That would be Nice too ... Many possibilities eh ? ...

Har’, all the PVC fence posts are 4” X4” and larger... but they do make a 2” X 6" , that could be made into an end channel by sawing off one of the edges...

http://www.lowes.com/pd_87348-73428-730 ... facetInfo=

[bonnie]

I'm experimenting with a PVC brick ledge piece. It would make a nice window casing.

[cpinetree]

Moulded fiberglass parts would be really Terrific for Foamies , just door and window frames is all that’s needed really Maybe just a length of correct fitting fiberglass moulding that could be cut to fit and glued into place ... That would be Nice too ... Many possibilities eh ? ...

Har’, all the PVC fence posts are 4” X4” and larger... but they do make a 2” X 6" , that could be made into an end channel by sawing off one of the edges...

http://www.lowes.com/pd_87348-73428-730 ... facetInfo=

Looks like if you cut that right you could get a square tube and 2 Channels, out of each piece. Now that would be super thrifty!

google searching for pvc channel & pvc square tubing brings up alot of other things but none nearly as inexpensive as the Lowes 3 channel 2x6.

[GPW]

I have to get my hands on one of those , just for some testing ...

[Hardryder56]

Wonder how hard it would be to mold a piece of PVC pipe, cut it along the length and then heat and mold it over a 2" form. Mmmmmm maybe I have a project tomorrow.
Tom

[Jack B.]

I don't know what they do on the inside for structural strength, but the PVC plastic "planks" they make for the flooring on porches, decks and steps might could maybe be ripped lengthwise on a table saw with a vinyl blade. They come in a couple different widths I believe so you could end up with a pair of suitable size channels to work with. Might have to cut out some inside ribbing to make it a true channel but that wouldn't be that much trouble.

Also, not real thrifty but, there is aluminum channel in various sizes and thicknesses that could be used. Around windows and doors, anything straight would be a piece of cake. The amount needed would be well within budgets for most and it would last a l-o-n-g time. Wouldn't work around curves like teardrop rear hatches but cutting plywood arches for each side of those isn't that big a deal now is it?

----------------------

On a non-trailer but foam and wood idea. I'm thinking 'bout building a pedal powered catamaran and have a couple of thoughts/questions for (I suppose) the Geepster. My idea for the two hulls is to make plywood "I" beams with the top being wider than the bottom. Bathe them in the solution a few times and then do layers of foam sheeting between the top and bottom on each side to form the pontoons. Cover with a couple layers of fabric, glue and paint and add a thin metal strip along the bottom and up the front for protection. The idea is the front to back plywood would help with strength and rigidity while the top plank gives something to screw/bolt/attach to while the bottom plate helps with rock, sand and hauling abrasion strength.

My question is, do you think that's enough protection from water? Pretty sure that I should use the pink or blue instead of bead board to cut down on water intake with the foam. This thing wouldn't sit in the water all the time, rather it's a few hours pedaling and then back in the garage or whatever. Of course if it works out then there could be a bigger one for longer time usage, but the way my plans go - baby steps, just baby steps.

Jack

[Kullas]

here is a link to a 2x2 gutter down spout http://www.guttersupply.com/m-contemporary-vinyl-square-downspouts.gstml I used this type of stuff in building RC planes. good stuff. I have not bought from this company but it gives you something to search for

[Jack B.]

How thick are walls on those PVC down spouts?

Jack

[wagondude]

On a non-trailer but foam and wood idea. I'm thinking 'bout building a pedal powered catamaran and have a couple of thoughts/questions for (I suppose) the Geepster. My idea for the two hulls is to make plywood "I" beams with the top being wider than the bottom. Bathe them in the solution a few times and then do layers of foam sheeting between the top and bottom on each side to form the pontoons. Cover with a couple layers of fabric, glue and paint and add a thin metal strip along the bottom and up the front for protection. The idea is the front to back plywood would help with strength and rigidity while the top plank gives something to screw/bolt/attach to while the bottom plate helps with rock, sand and hauling abrasion strength.

My question is, do you think that's enough protection from water? Pretty sure that I should use the pink or blue instead of bead board to cut down on water intake with the foam. This thing wouldn't sit in the water all the time, rather it's a few hours pedaling and then back in the garage or whatever. Of course if it works out then there could be a bigger one for longer time usage, but the way my plans go - baby steps, just baby steps.

Jack

Here is a start on some foam pontoons that may get you started. viewtopic.php?f=55&t=54589