Cutting Symmetrical Side Walls

[shootr]

Thanks for the pics AF, I was going for the 1/4" because I want to put a kayak rack on the roof and wanted to be sure it was strong enough to handle the static and dynamic loads when moving. In another thread I got some help on the strength of 1/8" vs. 1/4" - the weight penalty seems worth it to me for the extra insurance.

My first take on the actual sidewall construction was the outer layer of plywood laid flat, then 1x3 wood used to create a perimeter, and door and roof rack supports. These would be glued and screwed to the ply. Then 3/4" rigid foam cut to fit in the open areas between the 1x3's, also completely glued to the plywood. Then a full coverage of glue on that and the second layer of ply laid on top and screwed down to complete the "sandwich".

One question on your insulation: Is that the white foam w/ silver foil on both sides? I saw that tonight at Lowe's and was concerned how well the foil was adhered to the foam - in my store it wasn't, it just peeled off easily, intact. I was thinking of just white or blue board rigid foam so it could have the best chance to bond to the wood.

[Oldragbaggers]

As I plan my 4' x 8' Benroy-style trailer build on a Harbor Freight frame, I'm taking into account my limitations in skills for fabricating things. Currently I'm preparing to create the sidewalls out of 1/4" ply/1" rigid foam/1/4" ply sandwich/composite construction, with solid wood framing inside for structural support.

I know for a fact I will never cut 4 sheets of plywood separately and maintain the same profile on all of them. I haven't seen it mentioned anywhere so far, but is it feasible to expect I can clamp/screw all 4 sheets of 1/4" plywood together, draw out the profile, and cut them all at once? Or was it a given that is how it is done anyways.

Thank you.

I would probably cut one, tweak it until I had it exactly the way I wanted it and then use it as a pattern to cut the other 3 with a router.

[asianflava]

One question on your insulation: Is that the white foam w/ silver foil on both sides? I saw that tonight at Lowe's and was concerned how well the foil was adhered to the foam - in my store it wasn't, it just peeled off easily, intact. I was thinking of just white or blue board rigid foam so it could have the best chance to bond to the wood.

The white foam with silver on the faces is what I used on the top, because it was a lot more "bendy". The foam I used on the sides was rigid, the foam itself was a yellowish color and had kraft paper on the sides one side being silver. It did peel off easily, so when I glued the luan (used epoxy with fibers mixed in), I rolled out the adhesive on the entire surface, but concentrated on the wood parts.

Layed it on the floor with plastic underneath:


Mixed up the epoxy with microfibers:


Rolled it out on both sides:


Concentrated on the wood parts:


Put "gravity clamps" all over until it cured:

[Oldragbaggers]

Love them "gravity clamps"