Handcrafting A Fiberglass Camper Shell: A Comprehensive Guide

how to make a fiberglass camper shell

Fiberglass is a popular material for camper shells due to its strength and water resistance. However, creating a fiberglass camper shell requires careful consideration of the weight, flexibility, and cost of materials. One option is to use a wooden frame with fiberglass layers, which provides strength and flexibility while keeping costs relatively low. This method involves creating a wooden structure, such as ribs or blocks, and then covering it with fiberglass and resin. The number of fiberglass layers and the thickness of the wood will depend on the desired weight and strength of the camper shell. It's important to seal all edges and penetrations in the wood to prevent water intrusion and potential rot.

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Using a steel and aluminium frame

When making a fibreglass camper shell, you can start by building a steel and aluminium frame. This will be the base of your camper shell, providing the structure and shape for the fibreglass to be applied to. Here is a guide on how to make a steel and aluminium frame for a fibreglass camper shell.

First, you will need to decide on the dimensions of your camper shell. For this example, let's say you want to build a camper shell that is 6 feet wide, 12 feet long, and 7 feet tall. Once you have your dimensions, you can start gathering your materials.

For the frame, you will need 1 1/2" 14GA square steel tubing. You will also need welding equipment to join the tubing together. If you are not comfortable welding, you can also use bolts to join the tubing, but welding will create a stronger frame.

When designing your frame, consider the placement of windows, doors, and other features. You will need to add additional support to the frame in these areas. The frame should also have bracing on the top, bottom, and sides of the corners for added strength.

Once you have designed your frame, start by welding the tubing together to create the basic structure. Be sure to weld all the joints securely to ensure the frame is sturdy. After welding, you can add aluminium sheeting to the exterior of the frame. This will give the frame a smooth surface and provide additional strength.

When attaching the aluminium sheeting, use a combination of rivets and Sikaflex. Sikaflex is a strong adhesive that will create a watertight seal between the sheeting and the frame. Be sure to apply it generously to prevent leaks.

After the aluminium sheeting is attached, you can start applying the fibreglass. First, you will need to mix the fibreglass resin according to the manufacturer's instructions. Then, using a brush or roller, apply a thin layer of resin to the aluminium sheeting. Immediately apply the fibreglass matting to the resin, smoothing out any bubbles or creases. Allow the fibreglass to cure completely before applying a second coat of resin.

Repeat this process until you have applied several layers of fibreglass, creating a strong and durable shell. Remember to allow each layer to cure completely before applying the next coat. Sand the fibreglass between layers to create a smooth finish.

Finally, you can add any additional features, such as windows, doors, and interior fittings. Remember to seal all penetrations through the fibreglass to prevent leaks. And that's it! You now have a sturdy and lightweight fibreglass camper shell built on a steel and aluminium frame.

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Epoxy resin and carbon fibre

Materials:

  • Epoxy resin
  • Carbon fibre cloth
  • XPS foam
  • Thixotropic polymer
  • Release agent
  • Electrical tape
  • Nitrile gloves
  • Stir sticks
  • Cups
  • Brushes
  • Heat gun or acetone spray

Steps:

  • Set up a work station with ample room to work.
  • Gather all the materials you need and lay them out within easy reach.
  • Prepare your work surface by covering the edges of your worktable with electrical tape. Treat the table with a release agent to prevent the epoxy from sticking.
  • Cut and lay out your carbon fibre cloth. You will need enough to saturate with epoxy and create multiple layers.
  • Mix your epoxy resin.
  • Apply the first layer of epoxy resin to your work surface.
  • Lay the carbon fibre cloth over the epoxy, creating the first layer.
  • Apply another layer of epoxy resin over the carbon fibre cloth.
  • Place your XPS foam in the centre of the carbon fibre and epoxy layers.
  • Continue building up layers of carbon fibre and epoxy, alternating between them. You will need a total of six layers of carbon fibre and three layers of epoxy.
  • Use a heat gun or acetone spray to release any bubbles that form due to surface tension.
  • Once all layers are complete, cover the assembly with a layer of plastic and clamp it down to ensure a good press fit.
  • Allow the assembly to cure for several hours or as recommended by the epoxy manufacturer.
  • Carefully remove your carbon fibre and epoxy panel from the mould.
  • Repeat the process to create additional panels as needed for your camper shell.
  • Bond the panels together using a Thixotropic polymer to form the walls and roof of your camper shell.

Note: Always wear nitrile gloves and work in a well-ventilated area when handling epoxy resin and carbon fibre.

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Fibreglass and wood

Step 1: Choose the Right Wood

Select a type of wood that is strong, lightweight, and resistant to decay. Some good options include marine-grade plywood, basswood, cedar, or white oak. These woods are less likely to rot or decay when exposed to moisture.

Step 2: Prepare the Wood

Cut the wood to the desired size and shape for your camper shell. Seal all edges and surfaces of the wood with a waterproof sealant or epoxy to protect it from moisture. Drill holes for screws or bolts, making sure to oversize the holes and fill them with epoxy to prevent water intrusion.

Step 3: Create the Frame

Build a frame for your camper shell using the prepared wood. This will serve as the structure and support for the fibreglass shell. You can use wooden ribs or blocks to create a tubular structure that will provide strength and flexibility. Join the wood pieces together using screws, bolts, or epoxy, ensuring a sturdy construction.

Step 4: Apply Fibreglass

Cover the wooden frame with fibreglass mats soaked in resin. This process will create a strong and lightweight shell. Make sure to follow the instructions for the fibreglass and resin products you are using, as application techniques may vary.

Step 5: Finish and Details

Once the fibreglass has cured, you can add finishing touches such as windows, doors, and interior components. Seal all joints and openings with a suitable sealant to ensure water tightness. Consider using pre-cut plywood cabinets and components to customise the interior according to your needs.

By following these steps, you can create a strong, lightweight, and durable camper shell using fibreglass and wood. This combination allows for flexibility in design and provides a good balance between strength and weight, making it a popular choice for DIY camper enthusiasts.

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Aluminium sheets

Despite these challenges, aluminium sheets can be a suitable option for camper shells, especially for those who are new to RVing or looking for a cost-effective solution. Aluminium is rust-resistant and comes in a variety of colours, allowing for personalisation and customisation. It is also easier to repair than other materials like fiberglass, as only the affected area needs to be replaced instead of the entire sheet.

When deciding between aluminium sheets and other materials like fiberglass for a camper shell, it is essential to consider factors such as durability, maintenance, weight, aerodynamics, and cost to determine which option best suits your needs and preferences.

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Fibreglass and foam

When constructing a camper shell, fibreglass is typically applied in layers over a frame. In some cases, a resin coating may also be applied to enhance the strength and waterproof qualities of the fibreglass. One technique involves using pocket screws to attach plywood and a wooden frame together, filling the voids with expanding foam, and then covering the entire structure with a sheet of fibreglass. This method creates a well-insulated and sturdy wall.

The type of foam used in camper shell construction is typically expanding foam, which is injected into the voids between the frame and the fibreglass layers. This foam serves multiple purposes, including providing insulation and adding structural integrity to the camper shell. By filling the gaps, the foam helps to create a solid and unified structure.

When working with fibreglass and foam, it is essential to consider the compatibility of the materials. For example, when using extruded polystyrene (XPS) foam, it is crucial to choose the appropriate resin. Polyester resin can melt XPS, while epoxy resin will not. Therefore, careful consideration and planning are necessary to ensure the successful integration of fibreglass and foam in camper shell construction.

Another aspect to consider is the thickness of the fibreglass layers. While thicker layers may provide more strength, they can also increase the overall weight of the camper shell. Finding the right balance between strength and weight is crucial to achieving the desired level of durability and manoeuvrability. Additionally, the use of ribs or studs between fibreglass layers can enhance the structural integrity of the camper shell, allowing for better weight distribution and providing attachment points for furniture or other fixtures.

Frequently asked questions

Fiberglass is a popular choice for camper shells. It is strong, flexible, and lightweight. Wood is another option, but it needs to be properly sealed to prevent rot. Some people also use aluminium or steel, but these materials can be heavy and prone to dents.

This will depend on the type of vehicle and shell you have. For a truck, you can use brackets or clamps to secure the shell to the bed. It is important to use enough brackets to ensure the shell is secure and does not blow off while driving.

It is important to seal all the edges and surfaces of the plywood to prevent water from getting in and causing rot. You can use epoxy or a marine-grade sealant. Any holes or penetrations in the wood should be filled with epoxy before drilling.

One common mistake is not paying enough attention to sealing the plywood edges and surfaces, which can lead to water damage and rot. Another mistake is not using enough brackets or clamps to secure the shell to the vehicle, which can cause it to blow off while driving.

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