Over the top teardrop

[schnottus]

The floor came out awesome, looks like a bar top.

Thanks, I'm really impressed with the 2k clearcoat on wood. Very expensive stuff but super glossy, durable, and easy to spray. Just requires some good ventilation/reapirators.

[JasenC]

Ventilation!? we just can't have any fun anymore

[schnottus]

Pulled as much wiring as I could before attaching floorplate so I dont have to crawl around on my back so much. Junction box for the 7 pin wiring harness, and several flood lights underneath for offroading (they also light up when reversing).

[schnottus]

Making walls - i used 1/8 baltic birch laminated to xps foam by rolling epoxy on both. I would avoid West Systems foam epoxy roller covers, the foam delaminated on both of their rollers i tried without even finishing one wall.



I routed channels in the pink xps foam for frame members. Note the xps is 1.5in while frame is 1 inch tubing. There is at least a half inch of foam everwhere between frame and inside to avoid thermal bridging in cold weather.

[schnottus]

Dont forget to route wire channels before laminating interior wood



West epoxy roller

[schnottus]

Walls and floor attached

[schnottus]

Wall and front panel:

[schnottus]

Making a carbon plate, then turning it into light switch plates for the cabin:


After clearcoat:

[JasenC]

The switch plate's are cool man,

[schnottus]

Creating wall panels. I spliced together two 5x5 sheets of 1/8 blatic birch ply. Traced that out against the frame, then fiberglassed the bottom edge that will be exposed, and applied carbon fiber to the portion that is exposed inside the hatch.

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[schnottus]

Inside of wall panel was given a skim coat of epoxy. I then glued the sheet on the frame with Teroson 939. I used a sheet of plywood, many clamps, and some steel bars with wedges to apply pressure across the entire wall. Also gluing the kitchen counter. You can never have too many clamps.

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[schnottus]

All panels attached, started filling the seams and any flaws or voids in the plywood with thickened epoxy.

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[schnottus]

All seams were filled and chamfered, then 4 inch wide fiberglass taped.

Also stained the side panels purple, this will be covered with carbon but is still an important step.

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[schnottus]

sanded the fiberglass seam tape to taper it into the rest of the body. Then applied a layer of fairing epoxy to flatten everything out even more before sanding and finally putting 7oz fiberglass over the entire center of the camper (side walls will be carbon).

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[schnottus]

Putting carbon fiber on the side walls. This was a huge step. I was a little nervous because this is by far the largest piece Ive layed up. Before this it was just kayaks and small parts out of carbon.

I filled the various holes for roof rack and wiring with silicone plugs, then used modeling clay (sanded flush) to make it flat for epoxying. Make sure to carefully record where the holes are so you can drill them out later.

Time is of the essence when working with this large of an area. I premeasured out several large cups of epoxy and wrote on them how many grams of hardener they needed so i could just drop them on the scale and mix cup after cup.

I prewetted the plywood with epoxy on a foam roller, then applied the carbon fabric taking care to not snag it too much. After much careful positioning to line up the threads, i then used a spreader to fully wet the fabric with epoxy.