
Fiberglass campers are a great option for those who want to travel with ease and enjoy camping without the hassle of setting up a tent. Building your own fiberglass camper shell is a challenging yet rewarding project that requires patience and attention to detail. The process involves creating a sturdy and waterproof structure by combining materials such as plywood, fiberglass, epoxy resin, and expanding foam. One popular method is to start by building walls with plywood and a Douglass Fir frame, filling voids with expanding foam, and then covering them with fiberglass sheets and epoxy resin.
There are various approaches to constructing a fiberglass camper, and one can choose from different levels of completeness offered by manufacturers. Building your own camper shell allows for customization and unique designs, but it's important to be aware of the challenges and potential mistakes that may arise during the process. With careful planning, research, and dedication, creating a functional and comfortable fiberglass camper is an achievable goal.
Characteristics | Values |
---|---|
Materials | Fiberglass, wood, plywood, resin, expanding foam, screws, fiberglass cloth, fiberglass screening, epoxy resin, fiberglass and resin combination, heavy-coated vinyl, aluminium, carbon fibre, polyester resin, epoxy, Divinycell H-80 foam, biaxial E-glass, gorilla glue, saran wrap, sandpaper, Mexican serape blanket, neoprene stripping tape, Velcro, nuts, bolts, washers |
Tools | Fabric scissors, hand saw, Dremel tool, power drill |
Skills | Patience, research, creativity |
Platforms for research | Google, YouTube, Amazon |
Working space | Garage |
Steps | Prepping the mold, applying gel coat, fiberglass coating, mold stacking and bonding, insulation, build-out interior |
What You'll Learn
Prepping the mould
Once the mould is ready, the next step is to apply a layer of white gel coat. This gel coat serves as the outermost layer of the trailer's shell, providing a durable, non-porous, and flake-proof finish. The pigment mixed into the gel coat ensures that the trailer maintains its white colour for an extended period. Additionally, the gel coat simplifies future exterior repairs and maintenance.
After the gel coat has cured, it is time to apply the fiberglass coating. This process involves combining thread-thin, flexible glass with resin and spraying it into the mould. The combination of glass and resin forms a strong polymer that stands the test of time.
The next critical step is mould stacking and bonding. This involves placing the top mould onto the bottom mould, creating a capsule-like shape with a seam along the 'top and bottom buns'. Perfect alignment of the moulds is essential before proceeding to the next step.
The final step in the mould preparation process is to enter the interior of the capsule and overlay fiberglass and resin along the seam. This transforms the two mould pieces into one seamless unit. After removing the mould, you are left with a one-piece travel trailer exterior, ready for the next steps in the manufacturing process.
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Applying gel coat
Preparation:
- Ensure you have the necessary safety gear, including gloves, a respirator, and goggles. Gel coating can be hazardous, so adequate protection is essential.
- Prepare your work area by taping off sections you want to protect from overspray and laying down tarps. It is crucial to work in a well-ventilated area to avoid inhaling fumes.
- Clean the surface to be gel coated. Use acetone as a cleaning agent, and start the gel coating process soon after cleaning to prevent dust and contaminants from resettling.
- If applying gel coat over an existing gel coat, thoroughly sand the surface to ensure proper adhesion. For painted surfaces, completely remove the paint before proceeding.
Mixing the Gel Coat:
- Measure the resin using mixing cups and work in small batches to avoid waste.
- If using pigments to colour the gel coat, add them before adding the MEKP (methyl ethyl ketone peroxide) catalyst. The amount of pigment depends on whether you're using pre-coloured gel coat or not.
- Add the MEKP catalyst, following the manufacturer's instructions. The amount added will affect the curing time, so adjust according to your needs and the ambient temperature.
Application Techniques:
- Spraying is the recommended application method for the best cosmetic results and minimal sanding afterwards. Use a gel coat spray gun or a paint spray gun with a nozzle of at least 2mm.
- If using a paint spray gun, be prepared to clean it immediately after use with acetone to prevent the gel coat from hardening inside.
- Alternatively, you can use a brush or a quarter-inch nap roller for application, but the finish may not be as smooth as with spraying.
- Apply the gel coat in multiple layers, allowing each layer to set (gel) before adding the next. The timing will depend on the temperature and the amount of MEKP used.
- Your final exterior layer should include wax to ensure a hard, tack-free finish. You can add surface seal or use wax paper/PVA.
Post-Application:
- Once the gel coat has hardened, start sanding with fine-grit sandpaper (320-400 grit) and work your way up to a finer grit for a smooth finish.
- Store any leftover gel coat in a cool, dry place, away from sunlight and heat sources. Polyester gel coat has a limited shelf life, so proper storage is crucial.
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Fiberglass coating
Step 1: Prepare the Surface
Before applying any coating, it is essential to clean and prepare the surface thoroughly. Start by removing any loose dirt, oil, rust, chalk, mildew, or loose coating from the fiberglass roof. Use a fiberglass cleaner and a fine steel wool or sandpaper to create a slightly abraded surface for better adhesion. Rinse and let the surface dry completely. Cover all joints and roof seams with coating tape.
Step 2: Apply the Fiberglass Coating
When applying the fiberglass coating, ensure that you use an un-thinned coating at the rate of 350 square feet per gallon per coat. For maximum performance and protection, two coats are recommended. Apply each coat at right angles to each other using a brush or roller. The first coat must be completely dry before applying the second coat. Maintain adequate ventilation and wear protective clothing during this process to avoid contact with fiberglass.
Step 3: Allow for Drying and Curing
After applying the second coat, allow sufficient time for drying and curing. Under normal conditions of 70°F and 50% relative humidity, the second coat may be dry to the touch within 1 to 2 hours. However, it is crucial to prevent any chance of "wash off" by not applying the coating at temperatures below 50°F or when rainfall, cold weather, darkness, or high humidity are expected within 4 hours of application. Ensure at least 2 hours of direct sunlight during this period. The coating will typically take 24 hours to fully cure.
Step 4: Clean Up
It is important to clean all brushes, tools, and equipment with soapy water immediately after use. Dried fiberglass coating can be challenging to remove from surfaces, so prompt cleaning is essential. If the coating comes into contact with any unintended surfaces, wash it off immediately.
Tips for a Successful Fiberglass Coating Application:
- Ensure you have adequate ventilation during the coating process.
- Wear protective clothing, including gloves and eye protection, to avoid contact with fiberglass, skin, or eyes.
- Do not allow the fiberglass coating to freeze.
- Follow the manufacturer's instructions and recommendations for their specific product.
- Practice patience and enjoy the process of building your DIY fiberglass camper!
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Mounting the truck cap
Firstly, ensure you have built the truck cap frame using PVC, following the measurements of your truck bed's interior length and width. The frame should resemble a cube with one open side, which will sit on the truck bed. Allow the frame to dry for 10-20 minutes.
Next, you will need a helper for this step. Spread a blanket on the ground, larger than your truck. Carefully flip the truck cap upside down and place it on the blanket. Apply adhesive insulation tape along the entire bottom edge of the truck cap, except for the rear hatch area, to ensure a tight seal.
Now, it's time to mount the truck cap onto the truck bed. Carefully lift and position the cap so that it sits evenly on both sides of the truck bed. Make sure it is placed correctly before proceeding.
To secure the truck cap in place, attach two aluminium hardware clamps against the truck bed cap and rail. Drill holes through the cap and rail, and use bolts to fasten the cap securely onto the truck bed rails. Additionally, drill a small hole for the wiring of the tail light assembly.
Finally, locate the brake light wiring and connect the wires to the high-mount brake lights. This step may be a little tricky, so take your time and refer to online resources or videos if needed.
By following these steps, you will have successfully mounted the truck cap for your DIY fiberglass camper shell. Remember to take your time, work patiently, and refer to additional resources if you encounter any challenges along the way.
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Wiring the brake lights
Firstly, locate the brake light wiring. Typically, you will be looking for a light blue wire that feeds the third brake light on the back of the cab. Confirm that you have found the correct wire by cutting it and stepping on the brake pedal; if the third brake light does not turn on, you have identified the right wire.
Next, you will need to connect the wires from your high-mount brake lights to the light blue wire you identified in the previous step. This process can be tedious, and you may encounter some challenges along the way. If you need additional help, online platforms such as YouTube can provide you with valuable tips and tricks by searching for "How to Wire Tail Light for a Truck Cap".
If your truck has a 7-pin trailer light connector, you can obtain a constant +12V connection from there. This is even easier if your truck is set up for gooseneck or 5th-wheel towing and has a light connector in the bed. Remember to add a 5-amp fuse in line, as most trailer harnesses are fused for 15-20 amps, while the dome light wiring is usually only 18-20 gauge.
Finally, ensure that your brake lights are properly grounded. Depending on the metal-to-metal contact between your truck and the camper shell, you may need to run an independent ground wire for the lights.
By carefully following these steps, you will successfully wire the brake lights for your DIY fiberglass camper shell.
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Frequently asked questions
To make a fiberglass camper, you will need materials such as industrial-length Velcro, a Mexican serape blanket, fiberglass screening, and a portable power station. You will also need tools like fabric scissors and a small hand saw.
The process for making a fiberglass camper involves first building walls from plywood and a frame, then covering them with fiberglass and epoxy resin. The walls and floor are joined using pocket screws, chopped strand paste, and more fiberglass cloth.
Some tips for making a fiberglass camper include choosing the right working location, taking accurate measurements of the truck bed, and sealing the edges of the windows properly to prevent leaks. It is also important to have patience and enjoy the process, as DIY projects can be challenging and mistakes are inevitable.