Creating A Fiberglass Camper Shell: A Comprehensive Guide

Fiberglass is a popular material for camper shells, but creating one involves a lot of planning and consideration. When making a fiberglass camper shell, it's important to think about the weight, flexibility, strength, and cost of the materials used. While materials like steel and aluminium may be sturdy, they can be heavy and difficult to work with. On the other hand, fiberglass is known for its high strength-to-weight ratio, making it a popular choice for camper shells.

One key consideration when building a fiberglass camper shell is the need for a strong frame and ribs to provide support and prevent cracking. Wood is a commonly used material for this purpose, but it needs to be carefully sealed to prevent water damage and decay. Additionally, the choice of adhesive and sealant is crucial to ensure the structure is watertight and durable.

Building a fiberglass camper shell can be a complex process, but it offers the advantage of design flexibility compared to using pre-made molds. It's important to carefully plan and consider the various materials and techniques available to ensure a strong, lightweight, and durable structure.

Using wood for ribs between fibreglass layers

Wood can be used for ribs between fibreglass layers in the construction of a camper shell. The wood should be soaked in resin to protect it from moisture. This will also add strength to the overall structure.

Wood is a good choice for ribs because it is lightweight, flexible, and strong. It is also easy to work with and can be used to mount things to the camper shell. However, some people may not like the look of wood as it seems 'medieval'.

One concern with using wood is the potential for decay over time. To prevent this, it is important to seal the wood ribs between the fibreglass layers. This can be done by ensuring that there are no exposed areas of wood and that all drilled holes are isolated.

When connecting the pieces of the camper shell together, it is recommended to use a combination of gelcoat, fibreglass, resin, and Sikaflex 221 on the mating surfaces. This will ensure a strong and watertight seal. It is also important to consider how you will route tubing or cables through the structure, as drilling holes can compromise the integrity of the wood ribs.

Overall, using wood for ribs between fibreglass layers in a camper shell construction is a viable option that can provide strength and flexibility to the final structure.

Epoxy resin and fibreglass cloth

Fibreglass cloth, also known as fibreglass fabric, is low in weight and becomes strong when combined with resin. It is often used for building composite parts, making moulds, and repairs. The heavier fabrics are stronger and build thickness more quickly, while the lighter fabrics are great for waterproofing.

When using fibreglass cloth, you can use either the "dry" or "wet" method. The dry method involves applying the cloth over a dry surface, while the wet method involves applying the cloth to a surface that has already been coated with epoxy. The dry method is often easier to execute, especially with thinner cloth, as the wet method can make it more difficult to position the cloth.

• Prepare the surface for epoxy bonding.
• Position the fibreglass cloth over the surface, cutting it several inches larger on all sides. If the surface area is larger than the cloth size, allow multiple pieces to overlap by approximately two inches. Secure the cloth in place with tape or staples if working on a sloped or vertical surface.
• Mix a small quantity of epoxy resin and hardener.
• Pour a small pool of the epoxy near the centre of the cloth.
• Spread the epoxy over the cloth with a plastic spreader, working gently from the pool into the dry areas. Use a foam roller or brush to wet out fabric on vertical surfaces. Properly wet-out fabric will appear transparent.
• Smooth out any wrinkles and position the cloth as you work your way to the edges.
• Check for any dry areas and re-wet them as necessary.
• Use a plastic spreader to squeegee away excess epoxy before it begins to gel.
• Trim the excess and overlapped cloth after the epoxy has cured.
• Re-wet the underside of the raised edge with epoxy and smooth it into place.
• Coat the surface with epoxy to fill the weave before the epoxy cures completely.
• Follow the procedures for final surface preparation, which may include sanding.

For the wet method, follow these steps:

• Prepare the surface for epoxy bonding.
• Pre-fit and trim the cloth to size, then roll it up neatly.
• Roll a heavy coat of epoxy onto the surface.
• Unroll the cloth over the wet epoxy and position it.
• Work out any wrinkles by lifting the edge of the cloth and smoothing from the centre with your gloved hand or a squeegee.
• Apply a second coat of epoxy with a foam roller, ensuring you apply enough epoxy to thoroughly wet out the cloth.
• Remove excess epoxy with a spreader, using long overlapping strokes. The cloth should appear consistently transparent with a smooth cloth texture.
• Trim the excess and overlapped cloth after the epoxy has cured.
• Re-wet the underside of the raised edge with epoxy and smooth it into place.
• Coat the surface with more epoxy to fill the weave before the epoxy cures completely.

When working with fibreglass and resin, it is important to work in a well-ventilated area and wear proper safety clothing, including a respirator mask, gloves, and eye protection.

Marine plywood and fibreglass

When building a camper shell, it's important to consider the weight of your materials. For a camper shell, you don't need as much fibreglass as a boat because it doesn't need to withstand the same impact forces. You can use thinner fibreglass layers, but you may need to add some kind of reinforcement between the fibreglass layers to prevent cracking and add strength. One option is to use wooden ribs, which can also provide a good surface for mounting furniture and other items inside your camper. Another option is to use extruded polystyrene (XPS) between the fibreglass layers, but you need to be careful that the resin doesn't melt it.

If you use plywood, it's important to seal it properly to prevent water damage. Anytime you drill a hole or cut the plywood, you should seal the exposed edges and faces with epoxy or another sealant. This will help prevent water from seeping into the wood and causing rot. It's also important to use marine-grade sealant and preferably one that is UV resistant for any external applications.

In terms of attaching your camper shell to your vehicle, you'll need to use sturdy brackets and consider adding backing plates to distribute the weight and prevent the bolts from digging into the wood over time. You'll also want to use a flexible seal between the wood and the vehicle bed to prevent constant chipping from vibration and movement.

Using expanding foam

When making a fiberglass camper shell, one important consideration is what material to use for filling in gaps and providing insulation. Expanding foam is a good option for this, as demonstrated by Matt from The Traveling Together Journal in his approach to building a fiberglass truck camper.

Matt starts by building walls from five-millimetre plywood and a one-inch by two-inch Douglass Fir frame. He then uses pocket screws to attach the frame and plywood together, filling the resulting wall voids with expanding foam. This step is crucial in achieving adequate insulation for the camper. The expanding foam also helps to seal any gaps or cracks in the structure, ensuring that the final product is well-insulated and protected from the elements.

After filling the wall voids with expanding foam, Matt covers the entire wall with a sheet of six-ounce fiberglass and coats it with epoxy resin. This step adds strength and waterproofs the structure. The combination of expanding foam insulation and a fiberglass exterior results in a camper shell that is both durable and well-protected from the weather.

Overall, using expanding foam is an effective method for insulating and sealing a fiberglass camper shell, providing both functionality and protection to the final product.

Clamshell fibreglass construction

To begin constructing a clamshell fibreglass camper shell, one must first build a frame. This can be done using materials such as steel or aluminium, but these materials can be heavy and inflexible. A more lightweight option is to use wood, which is also flexible and resistant to cracking.

Once the frame is complete, it is time to add the fibreglass layers. The number of layers will depend on the desired thickness and strength of the camper shell. For a camper shell, the wall thickness can be just a few millimetres, as it does not need to withstand the same forces as a boat.

To add strength and support to the thin fibreglass walls, wooden ribs can be incorporated between the layers. These ribs provide a sturdy structure that can also be used to hang things on the walls. The wood should be soaked in resin to protect it from moisture and increase its strength.

Another important consideration is how to connect the different pieces of the camper shell together. This can be done using methods such as gel coating, fibreglass and resin, or a combination of these with Sikaflex, which is a strong adhesive.

Overall, clamshell fibreglass construction offers a lightweight and flexible option for building a camper shell. By using a combination of fibreglass layers and wooden ribs, a sturdy and durable structure can be achieved.

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