TERRA6, Van cab and chassis 7*14, 4" Polystyrene

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Ok, walls done, box framed sufficiently for strength, outside corners protected, but the roof.
The roof.
What to do for the roof for damage protection?
I was thinking about all the options and the costs, seeking out cover solutions. Galvanized steel was about the most resistant and cheap. Trying to find with the least amount of seams to minimize water infiltration. Had a quote of $200 for the metal and $350 preformed and bent to fit.

Found a supplier on Craig's that would just about cover the entire roof. And give me electric power as well for about $450.
This was great!


So I went with solar panels to protect the roof and give me 1360 watts of power at the same time. Win win.
I was considering solar anyway, so why not use it to cover and protect the roof? The tempered glass is incredibly strong on these and made to be resistant and durable.
Would never have to worry about having to recoat the roof.
Turns out that I could get 80" panels to cover my 84" wide roof which would attach perfectly to my inset boards on the roof. Perfect, what a stroke of luck. Place as many would fit up there and I had solar energy to boot. Managed to get 4 up there, cover all of the roof except for about 14", and only cost $115 per panel.
They weren't too heavy and from my test, believe that the roof could withstand the 50lbs per panel.
Ideally, hopefully, maybe. You know what I do.

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We never stood on the roof… for me , there was no real reason to … I’ve been making foam RC airplanes for almost 50 years now , so I had no worries about the structural integrity … And we’ve tested crashed these Foamies in most every way possible , so are well aware of the Strengths and weaknesses … Here’s an example of advanced Foamie testing … https://www.youtube.com/watch?v=tAh2EW0Hd0M

Thats hilarious, right into the tree. Why do planes go right for the tree when there is so much empty airspace?
Thx for the chuckle.

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So here's a pic of my PMF that was on the wheelwell section that I cut out. It has stayed flexible and pliable.
Think that with TB2 50/50 mix, would be hard and rigid.

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Another pic of before and after paint.

[GPW]

“ I had accidentally impacted and penetrated my PMF skin when a board fell against it, creating a 2*3" L shaped gash. Damn. Easy to repair, just caulked and painted but not impressive in the least.”
You really need to give yourself time to enjoy the best part of a Foamie , the “Self Healing” … Put it out in the Sun a few days , and most any comprsssion based deformity will fill back in … ( this also works with damp towels and Ironing the foam , just not too hot ot you’ll deform the surface … “ ) For small dents , just ignore them and they’ll go away …
If you rush in and fill the dents , when the foam underneath decompresses , you’ll have a slight bulge …

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Yes, I read this in your thread. Didn't work for my Polystyrene. Notice that circular dent that I mentioned in the driver's sidewall?
It was there over a week for sure, in full AZ sun and didn't go away, unfortunately. Actually, now that I think more about it, it wasn't going away after weeks of being formed.
Appears that this doesn't happen with my foam.
So I've filled it in weeks later, on separate occasions and it hasn't popped out yet. It better not.
But then, it isn't the 100+F we get in the summer either, only cooler 70s.
And the gash that I mentioned, it penetrated and cut through the fabric. That wasn't going to self heal.
That's the only thing that has disappointed me so far. Maybe because of my glue dilution as stated earlier.

But then I used about 10 gallons diluted. If I used undiluted, would have required 15 gallons which at ~$30/ gal for TB3, would have been almost $500 in glue. It would still have been$300 with TB2 undiluted. If I didn't get my materials at great prices, would have seriously questioned the validity of the whole approach. For a bit more money, would have built it with more durable materials or bolted on the used box and retained better value.
Imho, if you can't build it for less than half the value of a comparable, conventional, more solid unit of fiberglass, aluminum or steel skinned, wouldn't think it was worth it. A used item can come in at pricing only a little bit more than what one can build it for, excellent value.

As in my case, could of had a used, commercial fiberglass box for$1500. If the build was going to cost me over $750, would have been better to spend the extra money and buy the box. Faster, easier, more durable, proven and retained resale value.
The deck cost me about $450, fabric$100, glue about$200, paint$50, bonding glue$150, caulking$50, interior wood frame, glue and screws another$100. It all adds up very fast.
Not counting the foam which I would have used anyway, I'm in over $1100 and I would say that a foamie is not as durable as that fiberglass box which I could have bought.
And I got extra cheap pricing on my paint, as cheap pricing as possible on the glue, two of the major costs.
If I had to do it all over again...

[GPW]

You have done it your own way … “ Regardless of what anyone says on here, these builds and materials are not as durable as conventional.” ...

"But then, it isn't the 100+F we get in the summer either, only cooler 70s.” … Yes , it works very slowly this time of the year, it’s the HOT SUMMER sun that really does it …

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Approx. 5 weeks after I started, I pulled out of the kind owners yard and hit the road with a completed box and unfinished interior. The outside will do for now, a bed, shelves, counter and seating only on the inside. I will make do with battery powered LED for now, had lots of batteries.

The interior needed doing, solar hooked up, interior build and finish were all on the agenda.
First trip, about 2 hours highway. No issues, set cruise for 65 mph all the way. No noise, vibrations or weird handling issues. But then I drive carefully, or so I'd like to think.
Stopped for supplies, new propane tank, and hit Lowe's for some plywood to finish the counter doors. The parking lot is a great place to work, cause if you need anything, just run back inside. I did, for screws, boards and trim. Even stayed overnight and continued the next day. Mighty helpful and friendly folks at Lowe's.
The next day was major highway, 75 mph and lots of trucks.
Buffeting sidewinds of course with a tall box, but expected.

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Headed out on the highway, looking for adventure, in whatever comes my way....

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And the sun sets, on TERRA6.

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Even managed to attend a very popular, local get together. Camped among my fellow enthusiasts.
Golden sunset blessing us all.

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Inspirational words, to motivate us all.
Instead of a bumper sticker, I stencil painted my own.
To all who pass me, as I slowly trundle along.

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So the interior is progressing, first cabinets, then shelves, cabinet doors, bolting down the seats, connecting solar panels to controller and batteries.
Cover the ceiling, add some decor, try out a novel clothes storage method, reinforce the cabinets with a wall panel simultaneously boxing and strengthening the entire box. Cabinets and shelves built with the same purpose. Used the existing ceiling, walls and floor as parts of the cabinets and shelves, thus requiring to only add two sides to keep the weight minimal.
Used homemade sliders and sliding doors to keep costs down. Everything inside will be in a basket, tote or box.

Everyday, when not socially occupied, try to do a little bit and progress. Slowly but surely, and consistently, things get done. Every single item completed, makes me happier and increases the feeling of accomplishment. I've built a class B+ RV. Or one could call it a converted cube Van. Size approximates the newer Euro style vans, which was my objective.
A foamie? No one has ever heard of that.

The few who have seen it, have been impressed with what can be made with 4" styrofoam 4*8 sheets.
So far, I've driven a total of approx. 10 hrs, mostly highway speeds, and nothing has fallen off or apart.

The interior is coming along, flooring done, wall coverings 50-75% complete. Enjoy my daytime comfort seating that transforms to an evening bedroom, with the drop down Murphy bed and full mattress. Still working on placing, storing and arranging, you know, a place for everything and everything in it's place.
Went to an RV show and checked out the mega dollar rigs. Granite flooring tile?! Unbelievable what one can get for $250+k.
I was happy to install LED strip lighting to brighten my world, powered by the sun. Very bright, and inside now, I can have daylight on demand, 24/7. Don't really need windows, it's so bright now.
But I'm still considering a few.
Weakening the walls is a main concern and stress cracks.

Haven't taken too many interior pics, pretty standard stuff. But here's a look at some interior style. Looking for deep colors in a color scheme that promotes quiet calm I would like to call it. Still finalizing colors, trim and contrast hues. Doing some test boards and panels, various paint types and tones. Stain, polyurethane, paint or combinations. Deciding as I go along, depending upon what I can find locally, and priced right.

More pics to come, now that it is bright enough inside to do so.

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The interior, zzzzzzz....

Let's start with that oh so important rest and recovery mode, sleep and the bedroom.
Since we spend 1/3 or our day sleeping, possibly more, it's important to be comfortable, sleep well and be well rested. A converted dinnette and covered cushions wasn't the best. When you're younger, your body doesn't care. I thought a full and proper mattress was the way to go but bulky and wasted allot of space when not in use.
Murphy or fold out bed was the way to go. Gain back that space when not in use. When you run out of horizontal space, you have to go vertical.

So here's the bed in action, ready for a peaceful night's rest. All dependent upon where you parked it.

One of the advantages of no windows was that it was always dark when needed. Grab a siesta, or a full deep slumber anytime.

That stuff stored along the wall is clothing.
Thought this would be a great utilization of wasted space, leaving other space available. As well, quick and easy access when you get up in the morning. Roll over, pick today's clothes, get dressed, put up bed, and your off to start your day.
Clothes rolled and stored in large plastic ziplock. Compress, save space and also importantly, keep the dust from driving dirt roads embedding your fresh, clean clothes.
Used old tie down straps that I knew I was keeping for some future purpose.

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As you can see from the previous picture, pine and white is what I started with but find it a little too plain. Reminds me of the 80s look as well when this was the rage in cabins and cottages.
Want a little more color and emotion than just plain white or light neutrals. Pastel is too soft as well, more mid or deep tone. With all the light I have in there now, no problem.
So here's the bed up and the area converted into lounge, study, recline or dine with the seat up. Comfy and reclines too. The fold down table is airline style with a bottom tray sliding out even more and adjusts to ones comfort or preference. Or just out of the way, as needed.

Just completed one wall of tapestry, loving the look of it and the texture gives it visual appeal I think. Better than the white next to it. That section is next on the list to cover.
Loving the interior progress at this point. Every little item completed brings results and impact. One step closer to a finished vision. Yay!