Fuso Composite Camper - Under Construction

DzlToy

Explorer
For the last few weeks, I have been helping a friend of mine build this camper box in his shop. We are planning to bring it to OvEx in a few weeks and park it in the Featured Vehicle area. This is a bit of a side project for us, so it may take a while to complete and updates may be infrequent.

Highlights:

Construction: Composite Panels made to our specs

Insulation: Internal Foam Core with mil-spec spray on coating, R-value = R-25+

Interior Space: 144" L x 84" W x 80" H

Weight: Dry camper is around #650, competed camper roughly double that.

Acessories/Miscellaneous: 8,000 BTU HVAC, Queen bed, ample storage, kitchen and counter space, LCD TV, Laminate Flooring, Hehr Windows, 36" x 36" shower and 7' x 6' open living space in sofa configuration, panels bonded with Sika 252


3D model.jpg


Aerial View.jpg
 

DzlToy

Explorer
Panels stacked up in shop

Panels on Wall.jpg

Panels laid out for cutting door and windows

Door Cut.jpg

Shoe box assy completed

Roof Off.jpg

Roof temporarily placed to check fitment

Roof On.jpg

Panels being primed and coated

Coating.jpg
 
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DzlToy

Explorer
Roof trim bonded and screwed into place. Three layers of roof coating already sprayed on, two more to dto. Trim and SIKA are used to seal everything up, in addition to the spray coatings, so there are no concerns with dust coming in, water intrusion (leaks, mold, rot, etc). This also keeps out noise, which is vibration, as the walls are quite dense, but are still light weight compared to a traditional dry van or fiberglass box.

Everything is scuffed with 80 grit, wiped with Acetone and will eventually be painted with PPG industrial paint, once complete. This box may actually be sold. We are debating whether or not to build another one. It has been quite a bit of work. Looking forward to the show in Asheville.


Roof.jpg
 
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The Artisan

Adventurer
Thanks for the help brother. After researching and designing etc for over a year its nice to see it come together. What I thought could be put together in in 3-4 days turned into a nightmare 2 weeks part time. The Architecture and design background showing....:)
I will add it will have a road case cage made of 14 gauge broke steel...
The truck bed lining wont be on the pod though.


Kevin
 
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DzlToy

Explorer
There are numerous companies building all sorts of composite panels. Finding a good one that you can work with to build panels to your specs at a reasonable price is tough. Composite panels are used in residential construction, commercial refrigeration, boat hulls, campers, truck bodies and who knows what else, so you are not limited to someone who has experience building campers or RV's.
 

dlh62c

Explorer
There are numerous companies building all sorts of composite panels. Finding a good one that you can work with to build panels to your specs at a reasonable price is tough. Composite panels are used in residential construction, commercial refrigeration, boat hulls, campers, truck bodies and who knows what else, so you are not limited to someone who has experience building campers or RV's.
You can also go with a commercially built Cargo Body; http://www.morgancorp.com/nex-gen/features.php

Morgan will ship without a rear door and supply a panel to cover the opening.
 

DzlToy

Explorer
Made a bit of progress today (26 SEP), getting some trim installed, burned through a few tubes of SIKA and used up a few of our German stainless screws.

Red Oak blocks have been inserted and bonded into the panel for holding a 4" stainless steel screw. The panel edges are then sealed with SIKA 252 and bonded together. On top of that, a 16 gauge angle piece is installed (4" x 4") and that is also screwed and bonded with SIKA 252. The screws are not structural and niether is the Red Oak. They only serve to hold everything in proper alignment until the SIKA cures, which happens in about 24 hours.

After all of the trim is installed, the entire structure willl be re-coated with more spray on insulation coating and a Polyurea based coating to further ensure there are no cracks, leaks or gaps anywhere. These membranes are elastomeric in nature, so if there is any movement, water or other debris cannot infiltrate the structure at any point. Door and window openings will be treated the same, so there is no opportunity for leakage there either. Additionally, foam tape and weatherstripping will be installed, to keep the cold out and the heat in (or vice versa)


Front trim.jpg


case of sika.jpg


screws.jpg
 
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DzlToy

Explorer
You can also go with a commercially built Cargo Body; http://www.morgancorp.com/nex-gen/features.php

Morgan will ship without a rear door and supply a panel to cover the opening.
Ironically, there was a Morgan reefer box on the truck we are using for mock up, when it was purchased. It was quite heavy and too large, so it was sold.

We considered starting with another Morgan box, but they are SO heavy. Our completed camper is projected to weigh about half of what an empty Morgan box of the same size weighs. Composite panels are definitely the way to go IMO, for this type of build.
 

DzlToy

Explorer
After running into a few problems getting parts at the last minute, we pulled the plug on making the Overland Expo in Asheville. Additionally, the interested buyer could not produce funds, so the box is for sale. I will post pictures and details later this week.

20161007_182445_resized.jpg

New flat bed on the FE140. Hope to have the camper bolted down within the next week or so. The basic interior is complete, less a few pieces of hardwood flooring and installing the countertop.

Camper weighs about 750 pounds, as it sits with exterior and interior completed.
 

DzlToy

Explorer
Interior trim installed and framed in the front cabinets this weekend. It doesn't look like much, but everything seems to take forever.


20161023_190046_resized.jpg


20161023_190122_resized.jpg
 

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ColoDisco

Explorer
Just recently started researching this type of build and while I am 5 or so years out it is nice to have a write up like this. Subscribed!
 

dlh62c

Explorer
Looks like your off to great start.

Why only two windows, are there plans to add more?

Consider not going any smaller than a 28" wide entry door.

You can tape off the living space on the floor. It will give you spacial awareness as you move about the area.
 
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