Foamie Camper (Abbreviated) Build Journal

...ask your questions in the appropriate forums BUT document your build here...preferably in a single thread...dates for updates, are appreciated....

Re: Foamie Camper (Abbreviated) Build Journal

Postby greygoos » Sun Apr 08, 2018 7:03 am

Excellent job and a great presentation. Thank you for the inspiration.
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Re: Foamie Camper (Abbreviated) Build Journal

Postby John61CT » Sun Apr 08, 2018 7:20 am

Fantastic!

Love those fins
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Re: Foamie Camper (Abbreviated) Build Journal

Postby tac422 » Sun Apr 08, 2018 5:59 pm

Great Job !
I like it a lot :thumbsup:
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Re: Foamie Camper (Abbreviated) Build Journal

Postby jondbar628 » Mon Apr 09, 2018 7:17 pm

Wonderfully innovative and great craftsmanship. Another entry into the mythical Foamie Hall Of Fame.......jd
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Re: Foamie Camper (Abbreviated) Build Journal

Postby StanDahl » Mon Apr 09, 2018 9:02 pm

Thank you, thank you for your encouraging words! The Mythical Foamie Hall of Fame! (swoon) :)

It's not finished, I've continued to work on it. The latest is a cowling for the vent.
Day 129b copy.JPG
Day 129b copy.JPG (112.58 KiB) Viewed 1948 times

It turns out that Gorilla Glue does stick to painted canvas. Note the drain in the bottom center.

Day 129c copy.JPG
Day 129c copy.JPG (111.66 KiB) Viewed 1948 times

I haven't glued the center top piece yet, I want to do more to seal the stuff underneath that part first. After that gets glued up, then I'll shape it into something resembling an aerodynamic cowling, then cover it with canvas and paint it. I can only hope that I don't turn this into something that looks really stupid...

I'm hoping for something sort of like this, but not as narrow at the front (and of course, flipped around):
Scoop.gif
Scoop.gif (21.15 KiB) Viewed 1946 times
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Re: Foamie Camper (Abbreviated) Build Journal

Postby Don L. » Tue Apr 10, 2018 6:51 am

Wow too! Nice camper!
Thanks for posting your build. I enjoyed seeing how you built it, nice pics.
Link to my foamie camper build viewtopic.php?f=55&t=67321
instagram #don_leister_violin.rva
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Re: Foamie Camper (Abbreviated) Build Journal

Postby StanDahl » Sun Apr 15, 2018 9:32 pm

I made a couple of drastic cuts with a hand saw, then sculpted the cowling with an orbital sander and the shop vac hose hovering nearby.
Day 130b copy.JPG
Day 130b copy.JPG (124.34 KiB) Viewed 1857 times

I had to glue down some of the now exposed foam because on some pieces the slots were going in two directions, thanks to my cheapness with material (using scrap pieces). I got it to where I thought it was as good as it was going to get, then wrapped it in canvas. I put a piece of plastic tubing sliced in half under the canvas to keep the drain hole open.
Day 130c copy.JPG
Day 130c copy.JPG (110.67 KiB) Viewed 1857 times

I ran out of material and had to use thinner fabric on the inside, and layer the passenger side to fit a couple of scrap pieces in place.
Day 130d copy.JPG
Day 130d copy.JPG (102.1 KiB) Viewed 1857 times
The canvas was much more forgiving of the gaps underneath than I thought it would be. I'll see if I can make the overlaps look better before I paint it. I'll be taking it back out on the road this weekend, I hope to have it painted by then.
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Re: Foamie Camper (Abbreviated) Build Journal

Postby StanDahl » Sun Apr 15, 2018 10:56 pm

Just for reference, here's a before of the vent with no cowling:
Day 119c copy 4.JPG
Day 119c copy 4.JPG (83.38 KiB) Viewed 1853 times
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Re: Foamie Camper (Abbreviated) Build Journal

Postby StanDahl » Mon Apr 23, 2018 11:17 pm

The cowling got a paint job, and I took the camper out on a second shakedown cruise, this time to Death Valley.
Day 132i.jpg
Day 132i.jpg (159.72 KiB) Viewed 1792 times

It performed as I hoped it would, and I was able to set up the cheapo dropcloth awning.
Day 132d copy.jpg
Day 132d copy.jpg (120.78 KiB) Viewed 1792 times

Eventually there will be another that will come off of the back end and join this one to make an "L" and cover more area.
Day 132f copy.jpg
Day 132f copy.jpg (126.08 KiB) Viewed 1792 times

I threw an Aluminet tarp over the camper and awning to reflect sunlight, and that helped quite a bit to keep the heat at bay. It's not pretty, but it works.
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Re: Foamie Camper (Abbreviated) Build Journal

Postby Tucson_John » Wed Oct 24, 2018 8:09 pm

:thumbsup: This thing is radical! I love it. I don't quite understand the way you cut the curved part but I am totally new to this.
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Re: Foamie Camper (Abbreviated) Build Journal

Postby StanDahl » Thu Oct 25, 2018 10:02 pm

Thanks John! I'm not sure which curved part you're referring to - there are lots in this build! For the top of the frame itself, I used flexible strips of hardboard to trace a curve, then cut them out with a jigsaw.
Day 9a.JPG
Day 9a.JPG (131.52 KiB) Viewed 1597 times

I aligned them, clamped them together, and went over them with a sander to smooth them out and get them matched up. Then they were glued together...
Day 9b.JPG
Day 9b.JPG (130.25 KiB) Viewed 1597 times

...and then they were ready to tack onto the rest of the frame:
Day 9c.JPG
Day 9c.JPG (81.4 KiB) Viewed 1597 times


As for the foam, the hot-wire cutter did the dirty work all over the rest of the project.
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