Thrifty Alternatives ... Building Foam TDs Summary thread

Canvas covered foamies (Thrifty Alternatives...)

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Thrifty Alternatives ... Building Foam TDs Summary thread

Postby rowerwet » Sun Jun 16, 2013 5:12 pm

viewtopic.php?f=55&t=39373

I'm doing it by pages on this forum. ***** if you are using tapatalk the page numbers don't mean anything, sorry. If I ever get the time I might redo this all with hyper links to each post******
I like the idea of a foam camper, my next build will be foam, my current plywood build was finished with painted canvas an idea I got from this thread.
I started adding links to jump to the nearest tenth page or so, as the forum doesn't have an easy way to specify what page to go to in a thread this large. You can then jump to the correct page at the top. :thumbsup:

if anybody thinks I missed a good tip, let me know what and what page and I will add it. thanks

Page 1
-GPW starts with his poly mixture for perserving wood.
-painted canvas covering brought up
-cotton t shirts, old jeans, tie-dyed shirts for interior lining

page 2
-wood bows and aluminum tube sides, foam skin

page 3
-steel tube frame covered with painted canvas
-canvas fire hose to cover piano hinge
-cammo rip stop nylon covering
-fleece covering like speaker boxes are coverd in

page 4
-pictures of a td being coverd with TBII and canvas, then painted
-painted canvas covered sleigh from 1800's
-TBII glued guitars survived a flood
-Folboats were made with painted canvas originally
-TBII covered cardboard boxes proved waterproof

page 5
-TBII and canvas on modern high end wooden boat decks
-TBII melts foam?

*********Note!************
This effort was done to reduce the trouble it was to find information. Due to the chatty nature of our great members, there is plenty of off topic stuff.
Since this started as an experiment and doesn't have big name manufacturer money behind the effort, you are getting what you paid for, so don't complain.
All of us will be helpful if we can, but please don't come on here demanding help and complaining about the way stuff is presented.
You may think you've come up with a better idea, and you may have, this foamie idea is currently about four years old. Create a thread for your new idea, share the results and we can all learn.
I am now a successful foamie buildeder and have also developed foam kayaks using the same process. You can find the instructions for my own ideas of how to cover nearly everything with painted canvas here http://m.instructables.com/id/Poor-Mans ... -weatherp/ I wrote this based on ideas and builds found here.
the instructions for my successful foamie kayak design can be found here http://m.instructables.com/id/Sawfish-f ... t-wieght-/ the process also was learned here.
I designed and built the kayak to learn how to work with foam, different glues, and painted fabric skin. This experience allowed me to build my Mercury foamie with no plans, no wasted money and no errors.
The kayak cost about $100 to build, a tear will be a thousand minimum.
if you are the worlds best scrounger, start with a free trailer, you might come out cheaper, but don't count on it. Most of us find the rule of two (or three) true, it will cost twice what you think, and take twice as long as expected.
Learning on something cheap (the kayak) that is completed quickly, is the best way I know to build confidence and or convince a skeptical spouse you really can do this. ;) :thumbsup:
Trust us, this works :thumbsup: :thumbsup: :thumbsup:
Last edited by rowerwet on Sun Jan 31, 2016 2:34 pm, edited 8 times in total.
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby GPW » Sun Jun 16, 2013 5:17 pm

Well you’ve covered Most of it !!! Once the OT was removed... :R :lol: :lol: :lol:
There’s no place like Foam !
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Sun Jun 16, 2013 5:49 pm

page 6
-west system epoxy cost vs. TBII
-TBII only, coated cardboard box waterproof bucket
-TBII won't melt styrofoam
-awning supply places have canvas cheapest
-Raka epoxy vs TBII
-beeswax to lube screw threads
-TBII coated luan boil test

page 7
-making an awning waterproof
-thin TBII with water
-paint thinner cheaper than mineral spirits, both the same thing!
-blue foam and TBII TD with luan glued in for stress points
-check habitat for humanity stores for cheaper stuff

page 8
-Dow foams and TBII won't melt
-insullation co's cheaper source of foam than big box stores
-canvas better than bed sheet for strength
-GPW foam airplanes link
-adding inserts to a foam TD
-pinking the edges of the fabric
-wrap fabric from foam walls to ply floor to make TD stronger
-foam TD plan
-epoxy/foam TD pic and link

page 9
-foam TD model

page 10
-hot glue to join foam panels
-foam and wood TD pic
-sock theory
-cheaper glue than TBII?
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Sun Jun 16, 2013 6:18 pm

page 11
-TBII shell with no foam?
-paper mache TD usng layerd strips of cloth and TBII
-igloo cooler style TD with plastic walls?
-greenland kayak style TD using spray foam to make walls

page 12
-GPW painted TD model pics

page 13
-thrifty sources for cheaper lumber
-using a harbor freight trailer
-making a light enough suspension due to lighter weight of foam TD
-using a boat trailer to build on
-expanding foam for foamie repairs

page 14
-hot wire, electric carving knife, jig saw, router, hot poker to make cuts in foam
-are foamies hard sided? BEARS!
-log sided TT pic

page 15
-HD has 2" foam in 2'x8' sheets, pink
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Wed Jun 19, 2013 5:16 am

page 16
-BEARS!? park in the middle of a bunch of tents! :lol:
-oops paint is the cheapest source
-commercial painters may have paint they want to get rid of
-bending foam using heat, 190 degrees F, link
-DOW makes a kerfed foam sheet for bending
-solvent based contact cement melts foam, use water based
-arched roof TD for roof strength

page 17
-marine epoxy for joinin foam sheets
-GG also works
-foamies and hail?
-poor mans fiberglass PMF links

page 18
-using ultralight trailer frame for foamie
-covering the foam with muslin
-using dowels to align foam panels
-the fabric skin is the strength of the build
-using old burlap bags as the skin
-using exterior paint as the glue instead of TBII works, but possibly not as strong

page 19
-joining foam panels using potted inserts and dowels
-joining panels using 2 part silicone adhesive
-2 part silicone adhesive link
-how to make voids in the foam panels using an allen key, fill the void with epoxy as a mounting point
-Elmers pro bond will also glue foam panels, link to PDR website describing useto build a boat with foam and elmers
-making the epoxy filled foam voids have a machine screw threaded hole

page 20
-massive CNC pic and link
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Wed Jun 19, 2013 5:42 am

viewtopic.php?f=55&t=39373&start=300

page 21
-link to link on foam cutting

page 23
-using thin ply as inner skin instead of fabric
-resin soaked fabric as inner skin link
-bending foam roof to make it stronger
-paneling will glue to foam with TBII

page 24
-TTX foamie plan
-description of kerfing, heating, and bending foam to cover a car
Last edited by rowerwet on Wed Aug 07, 2013 6:29 am, edited 1 time in total.
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Wed Jun 19, 2013 6:33 am

viewtopic.php?f=55&t=39373&start=360

page 27
-using probond details
-thicker canvas better?
-use glue to stick on canvas fill the weave with paint
-this old house using canvas on house walls to prevent earth quake cracks

page 29
-foam must be attached to bare floor
-building td as a module off of the trailer
-sequence of foamie build
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby GPW » Wed Jun 19, 2013 7:22 am

Row , that’s coming along rather nicely , Thanks !!! A Noble effort ... :thumbsup: 8) :applause:
There’s no place like Foam !
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Thu Jun 27, 2013 6:46 am

viewtopic.php?f=55&t=39373&start=435

page 30
-military discount at Lowe's / Home Depot

page 31
-foam TD with no wood inserts for widows ideas
-aluminum frame instead of wood inserts?
-use mobile home roof coating instead of paint for exterior

page 32
-foam TD build links
-camping in bear country? talk to a local ranger
-plastic hinge for foam TD

page 33
-door with lip on the inside diagram
-check sail makers dumpster for remnants to use
-cattle panel arched and weleded to trailer to make a frame to skin with foam
-building sidewalls and wrapping them in fabric, then glueing fabric to fabric to assemble
-hot melt glue will soften in the sun, use care in a TD build

page 34
-foam and skin car building link

page 35
-swoopy foam TD sketch
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Thu Jun 27, 2013 7:16 am

viewtopic.php?f=55&t=39373&start=525

page 36
-using vinyle spackle to fill foam dents/voids
-makng foam shelves reinforced with luan
-punch an attacking bear in the nose, it has worked for some
-GPW TD buld pics

page 37
-don't cut foamie doors until after the TD is assembled

page 38
-pop up foamie idea and sketches

page 39
-Gorilla glue application tips
-Eaglesdare build pic

page 40
-thin GG to make it easier to spread
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Fri Jun 28, 2013 6:40 am

viewtopic.php?f=55&t=39373&start=600

page 41
-use pinking shears to keep loose threads from pulling out of the fabric edges
-Eaglesdare build pics

page 42
-GPW plans album link
-featherweight kayak plans link (foam/ply kayak)
-1" foam 2 lbs/cu. ft. VS. plywood 57 lbs/ cu ft

page 43
-idea of using PVC pipe as the TD frame
-question about filling the kerfs in the foam roof, filling not realy needed seems the best answer

page 44
-Eaglesdare eagle artwork pic
-basic Landscaping fromula for painting a mural on the TD links

page 45
-fabric skinning assembly picture
-reinforcement strip picture
-landscape painting idea picture
-how to make hard point inserts and cover them
-ideas for using inner tube, canvas hose, etc as hinge or seals under hinges
Last edited by rowerwet on Wed Aug 07, 2013 6:26 am, edited 1 time in total.
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Tue Jul 16, 2013 6:52 am

viewtopic.php?f=55&t=39373&start=675

page 46
-use pond liner or rubber roof coating to cover hinge, better UV protection
-you need to people to put on canvas, it stretches when wet
-flip the TD on its roof to do headliner?
-do the headliner fabric first, before putting the roof panels on

page 47
-apply glue to canvas, then stick headliner to roof foam, staple to spars to hold till dry
-thin the glue, whre it bleeds through the canvas it will cause the paint to crack
-dye the glue?
-tie dye finish?

page 48
-eagles dare pics of build
-use an iron at 150 to get rid of small wrinkles, (steam really helps) over 200 F melts foam

page 49
-use paint to glue on canvas, a stiff brush to fill weave, and work out wrinkles
-expanded metal under canvas to keep out bears? (would work for lightning protection if grounded to frame)
-keep food away to keep bears away!

page 50
-sharpen the edge of a small drywall mud knife to make straight cuts in foam
Last edited by rowerwet on Wed Aug 07, 2013 6:25 am, edited 1 time in total.
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby GPW » Tue Jul 16, 2013 6:58 am

:thumbsup:
There’s no place like Foam !
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Wed Jul 17, 2013 6:17 am

(sorry for the gap, took Storm Warning to Campmeeting)
viewtopic.php?f=55&t=39373&start=750

page 51
-using "reinforcement" strips to hide unintentional seams, or stick on auto trim
-you should have a drip rail over the door!
-rattling noise towing may be the plate

page 52
-eaglesdare first tow success
-rattle may be the coupler adjuster nut being loose
-put a pin in the coupler latch when towing
-rattle may be towing
-PC problems? GET A MAC!
-eaglesdare tow picture, Mickey mouse windows!

page 53
-wooden frame for door works best
-finish building before covering outside
-precanvas the headliner/roof
-building off the trailer would be easier
-foam TD sketch
-eaglesdare est. cost list

page 54
-more foam td sketches
-bring flashlights camping!
-eagles dare 1st camping trip
-rattle was a lack of weight!

page 55
-flip up counters are a bad idea
-foam TD towed nicely with a 1000 lb tow limit TV
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Re: Thrifty Alternatives ... Building Foam TDs Summary threa

Postby rowerwet » Thu Jul 18, 2013 5:54 am

viewtopic.php?f=55&t=39373&start=825

page 56
-painting application tips
-eaglesdare buld thread link
-spectra coating to keep bears out

page 57
-lego camper
-multiple foamies on the same trailer ideas

page 58
-make the fabric shell lke a slip cover
-convertable TD covers
-boiling water to fix foam dents
-TD playhouse

page 59
-foam standy ideas
-thicker foam =many times stronger
-canned ham sketch

60
-eaglesdare est weight
Last edited by rowerwet on Wed Aug 07, 2013 6:18 am, edited 1 time in total.
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