Building A Fiberglass Camper: Is It Possible?

can you build a camper out of fiberglass

Fiberglass is a popular material for building campers, with many enthusiasts opting to create their own DIY fiberglass structures. Fiberglass is valued for its strength, durability, and ability to create unique designs. One common technique involves using plywood and a wooden frame as a base, filling the voids with expanding foam, and then covering the structure with fiberglass cloth and epoxy resin. This results in a strong, lightweight, and seamless camper body.

There are various methods and materials used in the construction of fiberglass campers, including the use of different types of wood, foam, and epoxy resins. Some builders opt for a Poor Man's Fiberglass technique, using foam board and window screen or fiberglass for a lightweight and strong composite structure. Others utilize more complex methods, such as creating a fiberglass and wood sandwich construction.

Building a fiberglass camper offers flexibility in design and allows for customization according to individual needs and preferences. However, it is important to consider factors such as weight, cost, and the level of complexity involved in the construction process.

Characteristics Values
Cost The cost of building a camper out of fibreglass can be high due to the expense of fibreglass moulds, resin, cloth, fillers, and paint.
Weight Fibreglass is chosen for its tensile strength and lightweight properties.
Design Fibreglass allows for more design flexibility compared to other materials.
Waterproofing Fibreglass is waterproof.
Insulation Fibreglass provides good insulation when combined with expanding foam.
Strength Fibreglass provides high strength and lightweight structure when combined with wood.
Ease of Repair Fibreglass is easy to repair and can be patched with a bit of fibreglass mat and resin.
Durability Fibreglass is durable but prone to cracking and 'crazing' over time.
Aerodynamics Fibreglass allows for more aerodynamic shapes compared to aluminium.

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Using wood as a core material for your fiberglass camper

Wood is a popular core material for fiberglass campers, and for good reason. When building a fiberglass camper, using wood as the core material offers several benefits in terms of customisation, cost, and ease of construction.

One of the biggest advantages of using wood as the core for your fiberglass camper is the level of customisation it allows. Wood is a versatile material that can be easily worked to create intricate designs and personalised details. This makes it ideal for those who want to put their unique stamp on their camper. With wood, you can let your creativity run wild and truly make your camper one-of-a-kind. Whether you're an experienced carpenter or a DIY enthusiast, wood is a forgiving material that allows for a high degree of customisation.

Another benefit of using wood as your core material is cost. While the upfront cost of wood may be similar to or slightly lower than other materials, it's the long-term savings that make it a financially attractive option. Wood is generally easier and cheaper to repair than other materials. In the event of damage, repairing or replacing wooden components is often a straightforward and cost-effective process, especially when compared to the intricate and messy process of repairing fiberglass. With wood, you can also save on maintenance costs as it typically requires less ongoing upkeep than other materials.

Additionally, wood is a more accessible material for those who want to build their own camper. Constructing a camper with a wood core is generally simpler and less labour-intensive than working with other materials. Wood can be cut, shaped, and joined using standard carpentry techniques and tools, making it a more approachable material for novice builders. The use of wood also eliminates the need for expensive moulds, which are typically required for fiberglass construction, further reducing the overall cost and complexity of the project.

However, it's important to consider the potential drawbacks of using wood. One of the main disadvantages is weight. Wood tends to be heavier than alternative materials, which can impact fuel efficiency and towing capacity. This is particularly important for campers with smaller vehicles, as the added weight may limit mobility. Additionally, wood requires diligent maintenance to prevent issues such as rot, warping, or insect damage. Regular inspections, treatments, and protective coatings are necessary to maintain the structural integrity and appearance of a wood-constructed camper.

Despite these considerations, wood remains a popular choice for fiberglass camper cores due to its customisability, cost-effectiveness, and ease of construction. For those with a DIY mindset, wood provides the perfect balance of functionality and personal expression.

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The pros and cons of aluminium as a camper shell material

Aluminium is a popular material for camper shells due to its affordability, durability, and ease of maintenance. However, there are also some drawbacks to using aluminium for camper shells. Here are the pros and cons of aluminium as a camper shell material:

The Pros of Aluminium Camper Shells:

  • Affordability: Aluminium trailers can be thousands of dollars cheaper than fiberglass options, making them a more budget-friendly choice for first-time RV buyers or those new to camping.
  • Malleability: In the event of an accident, aluminium shines due to its malleability. Damaged sections of an aluminium trailer can often be removed and replaced, whereas a similar accident with a fiberglass trailer might require replacing the entire side.
  • Insulation: Aluminium campers typically have better insulation. They usually feature a layer of aluminium on the outside, a wood frame, fiberglass insulation, and dead air space, which provides added warmth.
  • Lightweight: Aluminium is a lightweight material, making it easier to transport and manoeuvre your camper. This can also help improve gas mileage, especially when compared to heavier options like steel.

The Cons of Aluminium Camper Shells:

  • Maintenance: Aluminium's matte finish tends to attract and hold onto dirt, requiring more frequent cleaning and maintenance to keep it looking its best.
  • Resale Value: Aluminium-sided RVs are more susceptible to dents and dings, which can negatively impact their resale value. Fiberglass RVs tend to hold their resale value better due to their durability and shine.
  • Aerodynamics: Aluminium trailers often have ridges, which can impact their aerodynamics. Fiberglass trailers are typically flat on the outside, resulting in better aerodynamics and improved gas mileage.

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How to join camper shell pieces together

Joining camper shell pieces together requires a strong adhesive, as the shell cannot be welded and mechanical fasteners can affect the structural integrity of the material.

Firstly, you will need to degrease the shell pieces with a product such as Permabond Cleaner A or isopropanol. Then, lightly abrade the pieces by either using a wet and dry grit paper (320-grade carborundum paper is recommended) or a red Scotchbrite pad. Finally, degrease the pieces again to remove any remaining residue.

There are several types of adhesives that can be used to bond the shell pieces together. Two-component epoxies, structural acrylics, and polyurethane adhesives are all strong options. For instance, you could use a black, toughened grade of cyanoacrylate, such as Permabond 735 low viscosity or 737 medium viscosity. Alternatively, for clear bonds, Permabond 731 could be used.

When joining the walls and floor of the camper shell together, you can use pocket screws, chopped strand paste, and additional fiberglass cloth to create a strong, lightweight, and seamless structure.

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The importance of tensile strength when building a camper

Tensile strength is a crucial consideration when building a camper with fiberglass. The strength of a fiberglass profile depends on the quantity, type, orientation, and location of the glass fibers within the composite.

Fiberglass is a composite material made by combining glass fibers with a resin matrix. The glass fibers provide strength and stiffness to the structure, while the resin holds the fibers together and protects them from damage. The resulting composite material exhibits high tensile strength, making it ideal for constructing lightweight and durable camper bodies.

The tensile strength of fiberglass is particularly important for its ability to withstand tension and compression forces. Glass fibers are strong in tension, meaning they can resist being pulled apart. This property is essential for creating a sturdy and durable camper body that can withstand the stresses of travel and outdoor use. Additionally, fiberglass is also strong in compression and can resist buckling under load. This makes it suitable for use in structural applications, such as camper walls and roofs, where it can bear the weight of the vehicle and any additional loads without failing.

The high tensile strength of fiberglass also contributes to its lightweight nature. Fiberglass profiles can be up to 75% lighter than steel while exhibiting similar or superior strength characteristics. This weight reduction is advantageous for campers as it leads to improved fuel efficiency during travel. Moreover, the lightweight nature of fiberglass makes transportation, handling, and installation of camper components easier and more cost-effective.

In addition to its strength and lightweight properties, fiberglass is also resistant to corrosion and ultraviolet (UV) damage. This makes it an ideal material for campers, as it can withstand exposure to the elements without deteriorating. Fiberglass is also versatile and can be moulded into complex shapes, allowing for greater design flexibility when creating camper bodies.

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The benefits of using expanding foam in camper construction

Using expanding foam in camper construction offers numerous advantages, from improved insulation and structural integrity to design flexibility and durability. Here are some detailed explanations of the benefits of using expanding foam in camper construction:

Superior Insulation

One of the primary benefits of expanding foam in camper construction is its superior thermal insulation properties. Expanding foam seals gaps, holes, and crevices, creating an effective thermal barrier that resists heat transfer. This results in a more comfortable indoor environment, reducing the need for additional heating or cooling systems. The foam's high R-value, which measures its ability to resist heat flow, ensures that the camper maintains a stable temperature, preventing cold air from entering during winter and hot air during summer.

Airtight Seal and Waterproofing

Expanding foam is excellent for airtight sealing, preventing unwanted air movement within the camper. By sealing all holes and crevices, it improves the energy efficiency of the camper, reducing drafts and minimizing energy consumption. Additionally, the foam's waterproofing abilities create a barrier against water vapour, preventing condensation and mould growth. This dual benefit of airtight sealing and waterproofing ensures a comfortable and healthy living environment.

Soundproofing

The use of expanding foam in camper construction also enhances soundproofing. The foam dampens sound and reduces noise penetration, making it ideal for campers used in noisy environments or on busy roads. This soundproofing ability ensures that the camper provides a quiet and relaxing space, even in less-than-ideal surroundings.

Design Flexibility and Customization

Expanding foam offers design flexibility and customization options. Its ability to fill gaps and reach hard-to-access places makes it easier to insulate and construct campers with unique designs and features. This customization potential allows for more innovative and tailored camper builds.

Longevity and Durability

Expanding foam is known for its longevity and durability. It is a wise investment due to its long-lasting nature, requiring fewer repairs or replacements over time. The foam's resistance to water, chemicals, and pests contributes to its durability, ensuring that the camper remains well-protected and structurally sound for many years.

Improved Resale Value

Proper insulation using expanding foam can enhance the resale value of a camper. The addition of expanding foam insulation demonstrates a level of care and quality that potential buyers appreciate. It adds value to the camper by addressing common concerns about temperature control and energy efficiency.

In summary, using expanding foam in camper construction offers a range of benefits, including improved insulation, airtight sealing, waterproofing, soundproofing, design flexibility, durability, and enhanced resale value. These advantages contribute to a more comfortable, efficient, and valuable camper, making expanding foam an excellent choice for camper construction projects.

Frequently asked questions

Fiberglass is a good material for building a camper as it provides structural integrity, is lightweight, and can be built without expensive moulds.

You can use plywood, epoxy resin, expanding foam, fiberglass cloth, and a variety of glues.

Some people use aluminium or steel, but these materials are heavier and more difficult to work with. Another alternative is to use Poor Man's Fiberglass (PMF), which is made from foam board and a material with tensile strength such as window screen or fiberglass.

Cost, weight, ease of construction and repair, and the environmental impact of the materials are all important considerations.

You can use wooden ribs or blocks between the fiberglass layers to provide something to attach to.

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