Thrifty Alternatives ..Building Foam Campers

[HandyAtLeast]

Today though was different, I had a vision of how to make the top corners of a bread loaf type camper in foam. Now to experiment with the kerf cuts to make the perfect 1/4 ball radii.

Yes, I was thinking about the breadloaf corners (as well as the Roswell) with the conpound bends. Not sure how the corner will form. I had thought that making a mold to fill with spray expanding foam might be a good idea for the corners. I do believe that with compound bends, the second bend will not be able to mirror the same bend as the first. i.e.- with a 12" radius bend for the first, you wouldn't be able to achieve a second full 12" radius bend due to the legs of the first bend. I might try it today.

As for the questionable content, I keep thinking of a bumper sticker that reads: "If this rigs a rock'n...Call 9-1-1!!!"

[bobhenry]

[. I had thought that making a mold to fill with spray expanding foam might be a good idea for the corners.

What about a kids large playground ball as a mold. Just fill it with foam and when solid cut carefully into 1/4 ths and you have your forms.

Just a dumb thought I'll go set down now !

[HandyAtLeast]

[. I had thought that making a mold to fill with spray expanding foam might be a good idea for the corners.

What about a kids large playground ball as a mold. Just fill it with foam and when solid cut carefully into 1/4 ths and you have your forms.

Just a dumb thought I'll go set down now !

That's just crazy enough to work!

[vreihen]

For those looking to do 3D bends, check out grid-scored DivinyCell and ProBalsa:

http://blog.jamestowndistributors.com/?p=871

These were mostly intended for use in a mold, but you can get some ideas for how to slot your own foam from them.....

[GPW]

V, pretty pricy , but their video tells it all ... http://www.youtube.com/watch?v=2Fumronk ... ded#at=155

[Miriam C.]

[. I had thought that making a mold to fill with spray expanding foam might be a good idea for the corners.

What about a kids large playground ball as a mold. Just fill it with foam and when solid cut carefully into 1/4 ths and you have your forms.

Just a dumb thought I'll go set down now !

That's just crazy enough to work!

If you didn't want a solid ball you could try cutting the ball in half, grease it up and spray it....The spray foam may act as a glue to the ball...Not sure!

[GPW]

Just a foamie idea ...

If that's Too Silly , just let me know ...

[pat g]

GPW,

I did use 4 spars to attach the roof foam to while the glue set. I needed something to hold the foam with the radius bend on the front.

Pat

[GPW]

Pat , using spars is fine , and Stronger...

[Anita Rae]

We have been watching this post and we are kicking this idea around and it looks like it is gonna happen. You guys are the best!

I don't know if I am going to be able to keep it thrifty but we sure like the lite weight idea. Hey...what can I say? I am woman; I spend money. LOL

We tried a couple of things with some stuff we had laying around the house. We used some 3M Super 77 spray adhesive to put two peices of foam together. It had to sit over night but right now I can't pull it apart without breaking the foam. There wasn't any foaming with this adheasive. This is leftover white insulation foam that we used to use in packaging for shipping products. It is probably what we will use in our build because it is all that is available in our area in 4x8 sheets.

I also am trying the 3M with a piece of fabric and it looks like it is going to work very well. The only problem that I see is that we will need to get the fabric in place on the first shot. There probably won't be any adjusting it because this stuff is really sticky. I would like opinions on using the 3M.

Another thing is that hubby and I talked about putting wood paneling on the inside because we like the looks of wood. But I found some wood grained fabric on Ebay and I ordered it. That way we can have our "woodsey" look without the extra weight of the paneling.

One more thing. A couple of pages back someone brought up using PVC pipe as a frame. We do a little work with plastics. The problem with that is that as far as I know, there isn't an adhesive that would bond the foam to the PVC. There really isn't a good glue for plastic to plastic bonding. JMO

[mikeschn]

Another thing is that hubby and I talked about putting wood paneling on the inside becaus we like the looks of wood. But I found some wood grained fabric on Ebay and I ordered it. That way we can have our "woodsey" look with out the extra weight of the paneling.

Chell said she wanted wood on the inside also. So I am probably going to stager the seams when I glue it up.

I really wanted to build something much smaller for my first foamie, and I think I've got Chell just about convinced. That would require only 1 seam instead of 2. And I wouldn't have to worry as much about keeping a large panel flat.

Mike...

[Anita Rae]

Mike, if you are interested, do a search on Ebay for "wood grain fabric". There are several different patterns and grains available.

One more thing. We are thinking of using white tub surround on the inside ceiling and ends. That way just the side walls will be fabric wood. This is also some stuff that we used in another project. It is very light and flexable(kind of floppy). I don't know if I can explain it. It isn't FRP but we found it in the same section as FRP. It goes together with the white H channel that you use for paneling. I wish I knew what it is called. Opinions please?

[GPW]

QUOTE: " I think I've got Chell just about convinced. "... Well, that's probably the hardest part of the build eh Mike ? .... The wife just ignores my " projects"... no helper , but no explanations required either ...

AR , are you talking about the beaded foam board (little beads ) ... That may Not be the best material ... Not as strong as the extruded Styrofoam... But with a good skin over it , should still be pretty Strong ...

[Anita Rae]

GPW, Yes! Thats the only kind of 2 inch styro sheets we can find around here. Most places carry the 3/4 inch but not the 2 inch. So would I be better of the purchase the 3/4 and double it? I asked in both HD and Lowes about them ordering the 2 inch, but I would have to order a whole pallet.

[GPW]

AR, I went through that pallet business with Loews ... I think that policy is STUPID ... You may want to check the yellow pages or an Insulation supplier in the area ... Most sell wholesale to businesses /contractors ...but they will sell you a few sheets if you explain what you're doing ... Seems these folks are always interested in a new application for their product ...

On the other hand , the bead board bends MUCH easier than the extruded foam ... and that's what they used on the roof of my Jayco TT ... I think they only used it because it's CHEAPER !! Used on a roof , spars might be a Good Thing !!!
Maybe a Hybrid ... extruded foam for the sides /walls , and bead board with spars for the Bendy parts ... ???