Stitch and glue pickup shell

[McTeardrops]

Has anyone used the WEST system? I'm thinking of a stitch and glue lift-up pickup shell, using 3mm marine plywood and the West systom, similar to the old Alaskan Campers. Sane idea? This would get my feet wet in this construction method, prior to getting my feet wet literally, in a boat building project.

[Wimperdink]

west systems are a favorite amongst boat building groups.... should do you just fine. That project will give you many experiances to prepare you for whatevers to come. I learned sooo much on a 3 panel canoe and its all stuff you just cant learn completely by reading.

[dwgriff1]

I have spent considerable time thinking of various pickup covers, campers and tonneaus!

My thoughts run to stripper designs, maybe along these lines:

http://butlerprojects.com/other/truckcamper/index.htm

I am intrigued with your ideas.

dave

[rmclarke]

Lenny,

That sounds like a great idea.
I'm very interested in 'stitch and goo' stuff. It's amazing the strength it gives to thin ply.

Richard

[AmyH]

I have been using West System epoxy on my build, and I love the stuff! I am sure you can put together a great stitch and glue shell for the pick-up! There are some great books out there that are worth looking at, including the book by Sam Devlin (he is out here in the NW). If you choose to do the project, keep us all informed. It sounds like a great project!

[angib]

Epoxy is just wonderful stuff - it's like welding, for wood!

The one glitch to your plan I see is that while the project would be great to learn using epoxy on, a pickup truck camper isn't the ideal application. It will have large flat areas that have to be stiffened to stop them flapping around and the easiest and thinnest stiffener to use will be some small wood framing. This is in contrast to, say, a canoe where there are many small panels that provide all the stiffening required because of their curved shape.

Then most of the joints needed on the camper will be right angles, so you'll loose the huge advantage of stitch and glue that it can make non-square, constantly-varying-angle joints with no effort.

So I don't think stitch and glue will give you any great advantage over regular glue and framing, except as a learning experience, and you will get the downside of having to mix epoxy each time you want to make a joint.

But I do have a plan ready and waiting for you:



Andrew

[Steve_Cox]

The beauty of stitch and glue is after you wire the plywood panels together you get to torture them into the multi-radii shape of whatever your building then apply the epoxy filets in the seams. I built a sailing dingy years ago it was a lot of fun to build, sail and row.

[dwgriff1]

Andrew, Your designs have long intrigued me! Has anyone built one of those alaska style campers? The commercially available ones are wonderful, but spendy and heavy.

I realize that much of the weight of a pickup camper is in tanks and goodies, and since I have a half ton pickup weight is critical, and the lower profile would mean better fuel effeciency. It seems to add up to a good solution.

Your plans suggsest torsion panels, and it seems it could be kept very light, but it is a big project.

Any encouraging comments?

dave

[angib]

The double-skinned panels were for insulation, but I don't think the second skin is essential - the lift-up part will be more flexible without them, but I don't see that as a big problem except in extremis (like trying to lift it by three corners only). I would be tempted to use 4mm (3/16") skin with 1x framing and a fabric inner skin/headliner over foam insulation.

I don't see this as all that much work - fitting out the inside as you want it must be at least half the total. Sure it's bigger than a teardrop, but then there's loads more space to work in.

My American/British translator fails at 'half-ton pickup' as I'm not sure what size that is - got a model and year? And the correct answer is Dodge, 'cos they are so good at publishing their body plans on the web....

Andrew

[dwgriff1]

Half ton in america has nothing to do with half ton!

My dodge is an '03 1500 with a load capacity of 1600 pounds, (not too much over that half ton). I have the small v8 4.7 l, with a 5 speed auto.

There are commercially available campers in the 6 to 700 pound range that are a bit smallish, but seem to be very workable.

dave

[Arne]

I used stitch/glue on my front curved portion (interior wall/ceiling) of aero-1... I fiberglass taped the outside of the interior portion after I did it.. found 1/8" ply did not have enough area to hold well, especially on a tear meant for towing on the road. The outside was normal, with cleats all along the edge, so no problem there.

[Juneaudave]

Has anyone used the WEST system? I'm thinking of a stitch and glue lift-up pickup shell, using 3mm marine plywood and the West systom, similar to the old Alaskan Campers. Sane idea? This would get my feet wet in this construction method, prior to getting my feet wet literally, in a boat building project.

I've used West, MAS and Raka. My personal favorite is MAS with the Slow hardener, especially on big surfaces. The reason is that I can lay the glass at night with the first coat...come back in the morning with the second coat...and apply the third in the evening and still get a chemical bond. West works great...but once you start...you have to stay with it!!!