Building A 4x4 Truck Camper | DIY Foam Composite Panel Walls
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- Опубліковано 29 вер 2024
- Progress on my DIY truck camper build! I share how I built the camper walls using DIY foam composite panels and attach them with fiberglass and epoxy resin. Building this camper with these techniques has proven to be a slower process than I had hoped, but I'm excited to see it taking shape.
What did I use?
Materials:
Totalboat Pour Foam = amzn.to/3fjXzWp
Titebond Wood Glue = amzn.to/3HVKKy6
Pocket Screws = amzn.to/3gPhLQk
All Fiberglass and Epoxy Supplies = www.raka.com
Tools:
Kreg Pocket Hole Jig = amzn.to/3pcCzWT
Makita Impact Driver = amzn.to/3LEbzJ6
Disposable Gloves = amzn.to/3LDD7i0
Respirator = amzn.to/3JueBhd
Irwin Clsmps = amzn.to/3gKDPf2
Bar Clamps = amzn.to/3gJWlUZ
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Music:
All My Shuffling by Silent Partner
Can't find your buy you a beer link again either 🍺🍺 please let me know
Always happy to share that link 😉
Its the second item down on this page: www.thetravelingtogetherjournal.com/support
@@TheTravelingTogetherJournal thanks Il get onto it soon
@@TheTravelingTogetherJournal A couple of beers each and 1 for good luck 🍺🍺🍺🍺🍺 enjoy! Did you receive it? From my wife Becky and I. 👍
@@coryyoung8289 🍻🍻🍺 We got it! Thanks Cory and Becky. It's much appreciated.
@@TheTravelingTogetherJournal no worries, if we ever meet in person we will buy you lunch and beers! been watching your channel since 2018 when we were on holiday in El Salvador you are very inspiring and make excellent content, and helped me a lot during the last 2 years of restrictions in Australia to keep saving and planning for my dream to return to El Salvador and Mexico when their is so much doubt. I felt depressed a lot and watching you guys made me feel better! Thanks
There you are! Finally someone using foam. There's a guy who built a rectangular travel trailer using what he referred to as poor man's fiberglass (high density foam covered in canvas and saturated with Tite Bond II. He dragged it all over the country and pretty much beat the crap out of it. And it held together. The only wood used was, if I remember correctly, plywood for the floor. Looking forward to seeing how your build turns out.
Thanks Raven
The "poor man's fiberglass" is pretty popular in the teardrop trailer DIY community.
It's always a balance between budget, strength, and weight.
@@TheTravelingTogetherJournal It's nice to see the Tundra is still on the road. I modified an old pop-up camper using high density foam covered with PMF. Turned it into a hard sided slide in panel trailer. During the initial phase of the pandemic. And I've used fiberglass over wood on a couple of small projects. PMF worked well but was very time consuming. I prefer fiberglass. Structurally really great stuff and easier to use.
@@ravenfeather7087 Thanks for sharing your experience raven. I like the fiberglass over wood construction. I feel it's a good balance of strength, weight, and rigidity. The downside for me is that it is taking a lot longer than the steel or aluminum frame builds I've watched people put together
It should float. 👍👊😎
Was waiting to see the progress. Good work Matt. I think you are putting a lot of trust on the pocket screws to hold the structure together on rough 4x4 only roads.
The pocket screws are mostly there to compress and hold the panels together while I do the fiberglass work. I'm no engineer, so I'm always just guessing whether or not something will be strong enough, but so far it feels pretty good to me and it should just get stronger as I add to it. 🤞
@@TheTravelingTogetherJournal Thanks for your response. I am aware that the glue is what holds the pieces together. I also use pocket screws in my woodworking projects. I am just not sure that in rough roads pocket screw/glue combination will work. Just my 2 cents.
@@boymeetsbush8232 Its all an experiment I suppose.
When I get the basic box done I'll take it on some local trails to test it out before I get into the electrical and plumbing.
Build is coming along great , thanks Matt !
Good see your progress!
👏🏼👏🏼👏🏼👏🏼👏🏼👏🏼
2 videos in 2 weeks...... ❤️🙏😀👍 And the build coming along nicely, great work and thanks!
Been looking forward to seeing the progress of your build. Good to see everything is working out alright.
Thy Layout looks different from what we say in the previous video, am I wrong?
Layout is still following the original plan with a .25" tweak here and there. Once I get a bit more done and get it out from under the tarp I think I'll be able to give a little better tour.
Nicely formed fillets, fibreglass tape and epoxy resin make for a phenomenally strong and supportive bond even before the final application of fibreglass cloth and epoxy resin!
With your superb foam cored panels you've effectively constructed a box shaped aircraft fuselage or yacht hull, both of which use this method to create immensely strong yet light, waterproof structures.
Your build incorporates the best construction methods for creating a structure that will be subjected to the demands of a 4x4 off road truck camper.
Thanks Felix.
I didn't know any aircraft were built like this, but I am pretty familiar with boats and figure I'm basically building a land-yacht 😁
that thing is going to be bomb proof!!
Man thats quite the job! Looks like it's coming along pretty good👍 I'm enjoying watching the progress. Thanks for the extra work on top of the work to share the progress with us!
Thanks Sean. Glad you're enjoying it
Dude!! I’ve been away from
UTube for a while and didn’t know u were building a camper. I’m so happy for u 2.
I honestly can not believe how long and far u have travelled in your old set up.
I love your videos and don’t know how u don’t have a million subscribers.
People are stupid!
Can’t wait to see the end product.
Excellent work guy!
✌️🇨🇦
Thanks Erick! Very kind of you to say.
About due for an update Matt! How you coming along?
Slow... hence no updates 😅
Hopefully I'll get the cabover done in the next week or two and that was my goal before making the next video.
I have a small truck Isuzu Panther, and i want to make a small camper truck. Your build inspired me. Thank you
That is awesome. Have fun with your build!
I freak'n LOVE this. So excited to see it come together!
Great!
Nice progress. I like the fact that you use wood framing. Here in below zero temp. my wood framed tc doesn’t sweat much from inside moisture as compared to other friends campers with aluminium framing. Of course frameless composite would even be better but not $ wise. Enjoy following your build. 🚚
Thanks Marc. That is exactly how I ended up deciding to go with the wood framing instead of metal.
Very funny :-))) Love it. YT ranking services - Promo>SM !!
Hey that’s a nice looking camper build and well thought out . That should be insulated great by the looks of your foam. I am currently building a camper too on my channel except it is aluminum glued to foam. Keep up the good work. Excited to see the finished product.
Thanks. Good luck on your build. I've seen some really nice aluminum/foam campers. Hope yours turns out the way you want it to
Great to see a new video, guys !! I love the wall design. Should be solid and much quieter than the single plié you had.
Quieter and better insulated I hope 👍
Top vídeo super cool thanks for sharing 👏👏👏👏👏👍👍👍👍👍
Top vídeo super cool thanks for sharing 👏👏👏👏👍👍👍👍
Nice to see the progress man! This is great content for all of us who one day would like to build our own rig! Keep it up my friend :)
Thanks! Will do!
WOW, That's what I call a properly made plyboard timber camper, It will last a very a long time, excellent job mate.
Thanks 👍
Very cool !!! Thanks for the updates.
Did you happen to weight your completed walls? It would be good to know the weight per square foot. I'm also curious if this would work with 1/8" luan instead of 1/4" plywood, to save even more weight. I suppose if you have firm and flat enough supports while pouring / expanding the foam that 1/8" would work fine too.
Yeah, as long as you can support the 1/8" luan, I don't see any reason it wouldn't work. If you chose to go thinner on the wood you may want to go thicker on the glass, which may negate some of the weight savings, but that depends on your application.
I have not weighed any of the completed panels. I believe the large panels will generally have a lower weight per square foot since they fave less framing per a square foot, but I will try to remember to weigh one an share that info.
Awesome. A buddy and I are currently building a camper with the same process. Ours will be similar design to the Vagabond or AT camper, with the pop up top. Definitely glad to be done with all the sanding and glassing!
Nice! I have a lot of sanding and glassing ahead of me still 🙄
I really like your approach to this build, definitely going to be sturdy
Nice job, good video to learn how to do.
Not what I was expecting. It's way more plywood than foam. Why not just fiberglass over 3" foam board?
If you looked at a cross-section of a panel it would be about 3/8" plywood and 5/8" foam.
The glass I'm using wouldn't provide me with sufficient impact resistance if applied over the standard xps foam board with 25psi compressive strength.
I would need to use thicker glass which would require more resin to wet out and/or a denser (more expensive, harder to source, heavier) foam board to achieve the same impact resistance/rigidity/strength as my diy panels.
If you're not on a budget the compost panels with structural foam core and carbon fiber skins seem like they would be awesome to work with and produce very light, functional results.
Fiiiiinally a new video on the build, yay! 😊 Please don't make us wait 4 months for the next one 🤣 Really excited to see the progress!
Thanks Sebastian. I'll get the next one out asap. But I do have to build it before I can make a video about it 😂
@@TheTravelingTogetherJournal haha we figured as much 👍🏻 we know the pain.
BTW, we will be shipping to Mexico in May and then travel MX, US & CA for a year. Would be great to meet up again and potentially even wheel together? Also, I could do another wakeboarding session on the Colorado river 👍🏻
@@sebastianlipp7649 Exciting! Stoked for you guys.
I'm hoping to get the camper usable by October, but we can always meet up for the day if you are coming up the west coast.
Hi, love your content! We at Kolify would love to work with you! We sent an email with details! Looking forward to your reply!
I'll check it out! thanks
What a mess using expanding foam. I have made several panels with rigid foam using epoxy and 4mm plywood on both sides. After curing there is no need to remove any excessive material or fine tune any edges.
XPS foam board is definitely a more popular way to go.
Sorry if this was asked before... wouldn't it be cheaper to purchase foam and bond t o plywood?
It would depend on the foam board and adhesive you choose, but xps and a good adhesive in standard caulking tubes would be a pretty similar cost.
I planned on doing this, but last year, when I was ready to start building panels I could not source xps foam in my area or online. I haven't tried online again, but they still don't have it at my local Lowes or Home Depot in anything besides 2x2 squares
Great idea making your own foam composite panels and your solutions for keep them from deforming during the foaming process (the hardest part). Also, using your other boat building techniques should result in a far superior product.
Have you weighed any of your composite panels to estimate an equivalent 4x8 plywood weight?
Thanks Mike.
I haven't weight any of the completed panels. I know they won't be as light as some of the foam board composite panels I've seen folks make with thin FRP skins, but hopefully not too heavy 😬
I'll try to remember to weigh the next one before I install it.
@@TheTravelingTogetherJournal Thanks. Weigh only if you are interested. Any size - I can interpolate. I think I already calculated the weight.
You done good! Your cost is way less than marine plywood foam panels at close to $400 ea, so you are already ahead. Your method is way lighter than house type campers with frame, siding, insulation, interior surface, and it is way more obtainable than marine ply or the marine ply foam composites. Also the marine ply foam composites do not have wooden ends for fastening and protection, so add another 7 lbs to their weight beside cutting out the foam to install.
I already had calculations for plywood+foam box beams to be used in my camper designs (paper and experiments only), so inserting 1/4"-nominal 5mm underlayment was an easy leap.
I calculated the weight using 2x5mm underlayment, 2lb cu ft foam, 3/4" x 1 3/4" fir strips (this may be wrong in size or wood), and fiberglass (1:2 fabric to epoxy). I get about 55lbs per 4x8 sheet or equal to about 1/2" construction plywood or 3/4" Okoume marine plywood (not foam). Marine ply +foam composite is 29lb + 7 lb strips is about 36 lbs, so not as far off from yours as some would think.
You would not be able to build a camper without a frame with 1/2" construction ply, but you could with 3/4" marine okoume using your boat building techniques - yours cost less than 3/4" okoume that goes for about $200.
FYI: FWC method of aluminum frame, siding, insulation, interior wall method shell comes in at over 100 lb per 4x8 sheet, so you beat them ... by a lot. And Alaskan is way heavier.
So, it seems you created inexpensive, dimensionally stable, insulated sheets made from parts that are readily available. Not bad.
Free labor goes a long way!
Look forward to how you solve the hard top issues lifting straight and sealing.
Again, thanks for the ideas.
@@mikemead2315 Thanks for sharing all that info Mike!
I'de say that's probably a pretty good estimate based on how heavy my panels feel compared to 1/2" ply. I might be a little heavier. The poplar ply soaks up quite a bit of epoxy when I'm glassing either side and the 2# foam is probably closer to 3# per cubic foot due to the restricted area that I am pouring it into reducing its expansion.
Sounds like you are going to have some well thought out camper plans 👍
@@TheTravelingTogetherJournal Yeah. Everything ALWAYS ends up heavier .... and costing more .... and taking more time! You are doing a nice job! Thank you for the inspiration!
Going to look Awesome 🤩
I missed this vid somehow.
It's really coming togeather great!!
Thanks, should have another update ready soon
8
how are yall doing? haven't seen any posts so just checking in on yall.
we're good. Just got busy with work n such, so nothing worth posting about. I'm still working on the camper when I can. I've probably made enough progress to put together another video. Just got to find the time 😅
Pavones ⚡
so awesome
Awesome!
wow
I am currently building a truck camper conversion on my channel, I am enjoying watching your progress. Good luck!!!
Looks great, thanks for the update on the build!
Thanks!
Update video on the build?
I just finished the section of the build that I wanted the next video to encompass, so... update video will be in the works
Thanks for asking
That looks strong and long lasting
💪 Haha Thanks
This is awesome! Just got an XL AWD Maverick. Might have to build something like this for my truck. Great video 👍
Thanks. Enjoy your new ride
Just found your channel as I am thinking of building a pop-up camper myself! Looking forward to going back through your content and catching up!
Welcome aboard Mike! Hope you find some helpful info
Gotta say...love following this build. The pour foam is unique and seems to work awesome!
Thanks Grant!
Coming along nicely. Now get it finished and head south of the border so I can live vicariously through your videos!
Amie has been asking me "Is it done yet" for a couple months now 😂
You are an impressive, clever and resourceful fellow. Are you sure you're a surfer? I'd love to see more construction videos.
More build videos will be coming after I get some more building done 😅
It looks like an interesting project you appear to be doing a very good job keep it up 😎👍
Thanks! 👍
where did you get the plywood lol??
This 5mm plywood has been the one thing that I've been able to consistently get around here 😅
@@TheTravelingTogetherJournal at home depot or something? or is there a wood store?
@@godboat. sorry your "lol" had me thinking you weren't asking a serious question.
I'm getting it at Lowes for the most part, but they sell it at my local lumber yard as well.
Its a poplar 5 ply underlayment produced by Revolution lumber
@@TheTravelingTogetherJournal haha awesome thank you! I'm trying to do the same thing as you but i got a bunch of xps, though it looks like the pour foam your using is much better than xps since it acts as adhesive too
@@godboat. I was planning on using xps but can't find it here in California.
The adhesive properties of the pour foam gives it an advantage but it also has the disadvantage of needing to poured into the panel so it limits your framing/construction options.
It’s so appreciated how you go step-by-step and explain things in such a calm manner you’re like the Bob Ross of Camper making. I’m just going to put a happy little wall right here… seriously could watch and listen to you do this all day. Can’t wait for the next installment.
😂😂😂😂😂. Now I just need a happy little popup and some happy little doors 😁
@@TheTravelingTogetherJournal yessss and soon you will and we all can’t wait to see. Can you somehow please make a surf siesta repeat shirt playing on this theme
@@mrad4234 Thanks for the positivity!