New to Forum

[asianflava]

Hi all, I'm new and this is my first post.

I am considering building a TD of my very own. I was looking around and most of the construction websites I have visited used standard ply construction.

I was thinking about making one where the wall panels are a composite sandwich structure. I was thinking of laminating 1/4ply (or luan) 3/4foam and 1/4ply (or luan) together and vaccum bagging it. I have seen houses constructed out of similar stuff. The only difference is they use thicker foam and OSB for the sides.

After the shell was complete I'd glass the entire thing to seal it up. Then install the aluminum on top, because I like the look. I figure that there would be many advantages to this construction.

Has anyone done or seen this kind of construction?

Does anyone know if this is a feasible method of construction?

[mikeschn]

The concept sounds feasable. I have never seen it done, as most people use stick built construction.

When you do your vaccuum bagging, are you going to have "studs" in the wall where you are going to drive screws through it, or attach things to it? If so, then you've basically got a vaccuum bagged, stick built construction!

Glass and aluminum would finish it off nicely! Keep us posted on your progress!

Mike...

[Chip]

Asian,,the one thing you will soon realize reading and watching is that anything,,and I mean ANYTHNG is feasible,,if you have the resources and the skills in a certain area then it becomes feasible,,I am not familiar with vacuum bagging so I will hold any opinion on the process,,I would like to see your progress though if ya do it,,,just consider all the aspects,,like Mike said ya got fastening issues to consider,,etc,,if those conditions can be overcome then go for it,,take a lot of pictures and keep us updated ,,and by the way welcome to teardrop world,

chip

[asianflava]

[quote="mikeschn"]
When you do your vaccuum bagging, are you going to have "studs" in the wall where you are going to drive screws through it, or attach things to it? If so, then you've basically got a vaccuum bagged, stick built construction!
Mike...[/quote]

Yes and no, not really studs but a frame round the perimeter of the sidewalls and top to act as a closeout. This would prevent moisture from getting to the core, finish off the edges and also serve as the "meat" for the screws and bolts. Kind of like a hollow core door.

[Joanne]

I was thinking about making one where the wall panels are a composite sandwich structure. I was thinking of laminating 1/4ply (or luan) 3/4foam and 1/4ply (or luan) together and vaccum bagging it. I have seen houses constructed out of similar stuff. The only difference is they use thicker foam and OSB for the sides.

As you are aware, that technique has been used in boat construction for a long time. If you figure out how to attach the panels together in a way that provides the required strength and prewire the panels for whatever electrical you plan on, it should work great. I like the idea of composites, even simple ones like we are talking about. Some of the foam coring that they use in boats would probably be less likely to absorb moisture.

If you decide to pursue building a composit tear, I'm sure we'd all love to hear about it. Start a web page!

Joanne

[asianflava]

I finished A&P school about 12 years ago (has it been that long?) and we did some projects in one of the structures classes. I haven't worked on anything like this since that class because I ended up in a totally unrelated field. Now I'm itching to do a composite project. I'm not too familiar with the marine foams. I was going to experiment with the foams available at Home Depot to see how they react to vaccum and to my resin.

I made a crossection drawing of how I want to join the wall to the floor decking. Forgot to add the screws that are perpendicular to the other fastner.



EDIT:
Hmmm the pic didn't attach but it is at:

http://www.tnttt.com/gallery/image.php?image_id=297

[R Keller]

Go for it! John at Tiny Tears (http://www.tinytears.cc) did vacuum bagging on his. I did my Road Toad (do a search on this site) with composite panels like you describe. Except I didn't vacuum bag it. I seriously considered it, but in the end I decided I could get enough clamping pressure using other techniques...

If you're going that route, you can probably get away with thinner material than 1/4". I used 5/32" Finland Birch plywood for my walls and roof, and 1/8" Baltic Birch for my hatch (ran out of Finland Birch). The walls and floor have 3/4" insulation and 1x2 nominal (3/4"x 1.5" actual) poplar framing. The roof and hatch have 1.5" insulation and the same poplar framing, but on end. It's all epoxied together with System Three Marine Epoxy thickened with plastic minifibers. The foam was Dow Styrofoam (blue board). It works very well for the purpose and is inexpensive.

You'll probably want framing around the whole perimeter, at the bulkhead wall, around the doors, at the countertop, and anywhere you want to attach shelves. A lot of my design work was figuring out where I needed framing and where I didn't. Since I used a fair amount of framing, the panels end up weighing slightly more than 1/2" plywood, but they are many, many times stronger. I can stand in the middle of my roof, for instance, and I feel no flex at all.

Rik

[shil]

Hey,

I thought about building something similar. In the end I opted to keep things simple. I used 3/4 inch ply for the sides of my tear, with a 1/4 ply - 1/2 foam - 1/4 ply sandwich for the 'curvy bits': the front, top, and hatch.

I didn't think that I'd save enough weight by building composite side walls. Mostly I just wanted to get things done.

Cool idea, however. I've always wanted to try 'bagging' something...

[Steve Frederick]

After the shell was complete I'd glass the entire thing to seal it up. Then install the aluminum on top, because I like the look. I figure that there would be many advantages to this construction.


Has anyone done or seen this kind of construction?

Does anyone know if this is a feasible method of construction?

'Flava
Yup! I did My woody in a similar way, except that I used glue with brads to hold together while curing. I incorporated blocking anywhere that would get a screw. Sealed the whole thing in 6oz 'glass. Worked too long in sheet metal trades, so I passed on the tin roof.
While the walls were open, I ran conduit for the wiring.
I built in a ledge to support the roof structure, assembled the headliner first, on that ledge, then remaining roof system. Check my build journal, I'm glad to answer any questions.

[jlrelp]

Hi

I have a friend that builds his tear drops that way. He also does not use any spars it is all form even the gallery hatch..

He can put the sides up in about a day you have to plan out the locataion of you electric to run inside the walll

He even has a kit out


If you want more info i can give you his email

[campadk]

Steve your tear is looking more than mighty fine! Can't wait to check it out!

After reviewing the weather forecast, looks like we'll be sitting under the tarp for the next 5 days at Fish Creek!