Box#3.0

[Shadewalker]

Ideas from Box#3 build.

3mm PVC (Sintra) adhered w Black Geocel 4500 to XPS (Pink Panther), with various amounts of PVC lumber inserted within the panels as extra "sticking" points
Duel wall enabling roof height expansion via linear actuators synced to a four unit controller.

Tested on back-ass washboard<<< roads w no speed limit. (Secure your loose items!) No asphalt queen here!

Cab over is NOT a sleep/person area. Its a Good area for storage of clothes& blankets.

Box is bolted to aluminum Z channel, which itself is attached to the truck frame via a couple aluminum box channels. Aluminum angle is used on all four outside corners as extra strength and 'brush beater' point of contact.

 

[Shadewalker]

PVC panel construction. Only a few pics as.....ADHESIVE,,everywhere!! Used a auto staple gun w stainless steel fasteners to keep the PVC components from sliding about until the adhesive set.

 

[Shadewalker]

Underframe attachments to truck frame.

 

[Shadewalker]

Shell & rear corner details. (with lots of clamps/jigs on rear lower corner work)

 

[Shadewalker]

Storage hatch construction.

 

[Shadewalker]

Box-shell skinning (PVC skins on cab-over & roof are meant for cosmetic purposes only & to protect the fiberglass under layer from UV.

 

[Shadewalker]

linear actuators interior view and results. (x4 actuators at 400lb each.) OVERKILL, much?!? ?

PS. the entry door insert that slides down to close doorway when camper is expanded needs work. Currently it is sitting in its slot via friction...a LOT of friction Next version will use locking drawer slides or a linear slide mechanism of some sort.

Interior wire work is now covered using a wire run protection/"purdy it up" kit

 

[Shadewalker]

Interior design ideas-part 1 of 2 (10 attachment limit hit)


many, many clamps are your friend when gluing carpet to hard angles.

 

[Shadewalker]

Interior design ideas-part 2 of 2 (10 attachment limit hit)

 

[Shadewalker]

Porch concepts.

Yes, a folding table gave its legs for this. It will be missed.

 

[Shadewalker]

Hoorah! The ********er fits!!!

 

[Shadewalker]

Installation of comforts of modern life in desert areas. (AC)

 

[rruff]

NOTE!! PVC expands/contracts something fierce in sunlight. So bubble city.
She is water tight and holding like a drum. However, plans are in progress planning a updated build, with either more studs in the walls, or skip pvc entirely, for cosmetic and hardpoint reasons. One might have better luck w adhesion between the PVC & Foam if one has a vacuum table setup, however, this is only a theory in the mind of this non-engineer.

I don't think expanded PVC would make a very good skin, for the reason you mentioned. Plus it should have a good paint if you want it to last. The gelcoated FRP skins would work better.

I've used expanded PVC as a core material with carbon laid on both sides, and that seems to work very well. The PVC needs to be sanded first. XPS should be prepped with sanding also... plus I like to perforate it with a wallpaper roller and work the adhesive (epoxy in my case) into the cavities. PLM Premuim would also work as an adhesive.

I've tried 3 different camper building methods now, and the one I think I like the best (easy and cheap) is using 1/8 luan skins over a XPS+ wood (1x every 1-2 ft) core, and then a hand-laid epoxy/fiberglass outer coating. It gives you a nice looking wood interior, and plenty of hard points for mounting internal stuff. You have to be very careful with exterior penetrations of course.

 

[Shadewalker]

(1x every 1-2 ft)

Can you elaborate on what 1x pertains to?
Ie, is it a 1x1 stud every couple feet?

Might you have a link or a picture available showing a completed panel as mentioned above? It'd be handy to visualize it.

Thank-you ?

 

[RoamIt]

I like some of your concepts Shadewalker! I really want to do a lifting roof on my build, trying to keep it short overall, so only place to go is up.

I was looking at various actuators/truck box lifts. Do you mind sharing the ones you went with? Are you going to use any kind of track system to keep things aligned?