D.I.Y Light weight sleeper using D.I.Y rail top components

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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Wed Oct 19, 2016 4:46 pm

This is the tooling for the skirt on the bottom of the trailer. You can see the lath for the reset

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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Fri Oct 21, 2016 11:49 pm

This is the part pulled from the lath tooling.

The parts will be used as skirt to cover the frame. Also with be used to make roof bends



Will use the tab one to the front one to the back then bond where they meet .



Today my axle was received. Four inch to narrow. I’ve bound the shell together.



So will have to cut apart. To make it so the wheels are covered will be too much work.
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Thu Oct 27, 2016 8:40 am

Now that you have made the outer shell time to add the foam. When you add can foam it is used to bond and inflate. The foam needs a gap to flow right and have no voids. A 1/8-inch will be great.. I have found by resting a little of the foam block on the tab works. Then add one layer of fiberglass mat over the foam with all paper removed. This is for better bonding. Do just one layer at this time. If you have a blowout from the can foam better to have on the inside. For me I made the blocks 203mm long. Eight inches long.
After inside mat has cured. Drill small holes between each block on the inside. YOU MUST add can foam where the void is vertical. Bottom to top. Just flip the shell. Remove extra foam. Add one more layer of mat to seal foam.
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Mon Oct 31, 2016 10:42 pm

When we did the fiberglass profile .It can be broken down to two parts the tabs & body. . Body is the space between the tabs.
The body is two layers of 1.5 oz mat then 7 oz woven. The tabs are at first two layers .As you do the foam it will add two more layers to the foam.
Most of the profiles on the web are for building structures So there on the heavy side. So if you deal with one of them tell that you plan to do light weight with foam. It would be better if you do your own profile.
I have dragged my heels to see how well bobwhite215 Aluminum composite teardrop build
_http://www.tnttt.com/viewtopic.php?f=50&t=67211 works out.
If it does it be just glue seal the edges and done..
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Tue Nov 01, 2016 4:25 pm

if you did a nice kit.
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Tue Nov 01, 2016 10:54 pm

The last post is a Chuki Teardrop Caravan .It's built using the tabs
https://www.youtube.com/watch?v=3erMv_MF4o4
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Wed Nov 09, 2016 9:44 pm

The way I did the cross pieces used to make roof bends
Will use the tab one to the front one to the back then bond where they meet .
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby tony.latham » Wed Nov 09, 2016 9:57 pm

saywhatthat wrote:The last post is a Chuki Teardrop Caravan .It's built using the tabs
https://www.youtube.com/watch?v=3erMv_MF4o4


What do you mean by tabs? It looks to me that those are built (probably at a factory) using fiberglass parts made by spraying glass/resin in a female mold.

Tabs?

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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Fri Nov 18, 2016 9:52 pm

Tony
The chukiki I'M sure it is made in tooling. BY tabs where a lip for the roof and sidewall.
As fast as the cut and hinge I so fast . if you where planning to do more than 20 a year I would do tooling for the whole frame..
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Fri Dec 02, 2016 12:21 am

I've move to grave shift . make it a lot hard to work on this trailer. To cold and dark . So will putter along.

I have add all the cross pieces.As the bends are flat. It's Very easy. After make parts from the last tooling That was posted . One for the top then bottom. ]
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Fri Dec 02, 2016 12:24 am

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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby MadMango » Fri Dec 02, 2016 10:11 am

I know how you feel about it being dark outside. Continue on.
Red will be the final color of your trailer?
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Fri Dec 02, 2016 11:51 pm

''Red will be the final color of your trailer'' by MadMango
I've not decided as of this time . The tooling I used . Was 26 inch of vinyl porch railing. I also made each piece .There 32 bond lines must be felled and sanded . Had I used the cut and hing .There be only 16 less.
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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Sun Dec 04, 2016 7:26 pm

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Re: D.I.Y Light weight sleeper using D.I.Y rail top componen

Postby saywhatthat » Sun Dec 04, 2016 7:30 pm

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