Well, I got the sample box today, and I've been playing with it. Cut about a 1"x4" piece of the plywood-PP core material and stuck it in boiling water. One side promptly came loose! So I cut off another piece. Same thing happened. Little or no glue on one side and the plywood just came loose from the scrim on the PP core. The other side appears to be bonded ok. Looks like a poor glue job.The change in ply type might affect the amount of bonding agent need per panel. The dry spots could be due to their switch in ply type. Different absorbsion etc. Cool project
The dust is really the only thing keeping me from fiberglass panels but it's not a huge issue...especially if they are a proven product. Also, I'd want them to come pre sanded for additional fiberglass bonding. I'll have to see if they have that option.I'll definitely contact them tomorrow. When I talked to the rep earlier about the plywood panels he didn't sound very enthused about them. Said they didn't sell many and that they didn't have any in stock, and it would take 4 weeks to get them. I wonder if it's a known problem and is getting fixed?
I'm thinking about the fiberglass skinned panels now. They are $208 for 1" but they seem real solid and have some advantages over plywood. The big disadvantage is fiberglass dust when cutting.
The PVC foam seems really solid also. That's ~$100 for 1" and I'd have to do the skins myself.
I didn't see that on their site, but they do list a panel with double thickness skins. The skins on the sample I got are ~1mm thick which seems like a lot for a single layer 18oz cloth layup, but I really don't know.Also, I'd want them to come pre sanded for additional fiberglass bonding.
I thought that also, his build thread has turned into a discussion of structural panels. Which he happens to be using, but still...Gunner207, if this conversation is clogging up your build, just let us know and we can go somewhere else. It's very helpful to be in on the ground floor of a discussion like this that's up to date but I would understand if you want it elsewhere.
I have been reading this thread since day one and I want to thank you! Please continue to share your wisdom and experience.This is absolutely fine with me. I think this makes sense. I got the heat turned on in the shop and cut the blank for the camper floor tonight. I'll start posting progress each day and will try to come up with as many methods as I can for joining panels. I have quite a bit of experience with composite construction, etc, so let's all pass thoughts and problems back and forth.
I really like using temporary fasteners for holding things together while adhesives / epoxy cures. There are also some flexible setting epoxies that I would certainly consider on a larger build. I am thinking of making a mold along each panel seam with thin stock either covered with packing tape or pva mold release and tacked in place with 23ga pins. Then I would reinforce all the seams on the outside with 3 inch bias cut fiberglass tape in epoxy. The whole framework could be a single lay-up.
Stay tuned for photos starting tomorrow and please all of you feel free to make suggestions, ask questions, or even offer critical input. I can adjust or even do some sample joints for ideas you might have. Remember in everything, it is so often the best case to not be an expert because then you don't know how it is supposed to be done.
That should be plenty strong if it's done well. Was the thickened epoxy fill on the edges tricky or difficult? Did you use wood powder or something else?This leaves the end grain of the other piece exposed on the outside of the corner so I filled that thickened epoxy, sanded and then used 6-inch fiberglass tape or bonded aluminum angle to it with 3m 5200. The aluminum angle is not welded (to answer an earlier question).