Use foam board with wire mesh and grout for home building. Pull wires through the foam board to tie the mesh to both sides of the foam board. Use great stuff spray foam to glue your joints together. Use any cementitious mixture to coat the wire lath to make a house. Use foam backed corrugated metal panels for the roof. It will not comply with local building codes because the government does not want you to escape their system.
Hey man, I appreciate the work you put into these videos, but I do have a few tips from my own testing on a similar project: 1- a larger sample size would improve the accuracy of the results, i.e. 2 or 3 tests of each glue/insert combination. 2- I recommend trying great stuff expanding foam! They also have a great stuff "construction adhesive" that applies with a foam gun and bonds as well or better than gorilla caulk adhesive! Also far less messy than the canned foam, and cuts with a hot knife blade far easier. 3- a Stanley "surfform" rasp/plane works amazingly well for shaving foam to shape (it's what they use to make surfboards), though dusty. 4- buy some Bosch "soft material" jigsaw blades! They have a wavy looking knife edge, model T313AW, that I've grown to prefer over anything else since they're not as dusty as a utility knife, cleaner cut than a circular saw, and no fumes like a hot knife! Thanks again for the work you put into these videos, it inspired me to tackle the biggest project of my life, a tiny home made entirely out of foam, and likely inspired countless others. I eventually plan on making plans/blueprints for others to follow, and instructional videos as well. None of this would have happened without you, so thanks again for putting this information out in the world. Peace and love!
One more thing, I've had great luck painting the fiberglass screen material on a whole 4x8 sheet, then cutting to shape with the jigsaw. It takes more planning to not waste material, but if you have the dimensions down ahead of time and shave to adjust fit with the surfform, its a HUGE timesaver. Then I puzzle-piece them together like you, and glue with great stuff foam and drywall screws to hold while it dries.
Great tips and SO great to hear I inspired you and gave you info to tackle such a big project!! That’s the main reason I made these videos to start with! It means a great deal to me to hear stories like this! Would love to see your project!
@@falkornomad I will definitely cite you as inspiration when I get around to making a video! Trying to finish in time for Burning Man this year. One question, do you sand or otherwise prepare the shiny, slick surface or the foam before painting? I've found it improves adhesion, but sanding dramatically increases labor time, and I was wondering if you found a faster way. I also heard rubbing alcohol dissolves the "skin" but haven't tried it yet.
I have been asked this previously and I have not noticed a shiny side… it was described to me a a physical coating that could be peeled off? Maybe the newer xps has this on it?? I have never treated the foam prior to glue or screening at all. That said, either way maybe a test is in order glue two shiny sides together and two sanded sides and see what you get. Let me know. Next time I’m in a hardware store I’ll see if it’s something new. Is it on both sides or just the side with the black printing on it?
♥the "project farm" style tests! I was glued to my screen for 27 minutes - SOLID. I will watch whatever length video you post. don't care about yt algorithms.
Glad you liked it! I try not to care about YT algorithms… but in an effort to get the info out to more viewers I’m realizing I have to. I prefer watching longer videos if it’s something I really want to know about, however it is easier to produce shorter videos. And since I never know how good my internet connection will be, uploading smaller videos is MUCH easier.
Thank you for the thorough ,informative ,no bullshit results. You come off as an intelligent ,interesting ,and show just how much baloney we eat each day while staring at the screen.I am a retired building trades guy from the city of Boston so I believe I can pick up on the real deal
I'm finding this so ridiculously interesting! I'm nearly done with my build and I wish I had learned about this sooner. Thanks for showing us these tests, it must have taken a lot of time & expense to find the best one.
You should inspect a hollow core interior door, like the old birch doors. They inserted a wood strip or blocks at the edge of the doors for mounting hardware but the door is a cardboard honeycomb in the center. You could probably do that with the foam without adding much weight. Makes a cleaner edge for front of cabinets and adds strength for screws. Just a thought…. I like the foam interlocking panels. Nice job!
Thanks for your very detailed comparison of glueing and screwing foam boards inspires me for this material selection for a light weight bicycle trailor with good thermal insulation!
Your ideas, methods, research is off the chain impressive! I'll watch what ever length video you chose. I'm just so thankful, impressed!! I had been thinking about using this insulation board but you bumped it up many levels! I love your brain!!!
Just saw both videos on this. Thank you very much. You just saved me time and, most importantly, MONEY! I always wondered about ridged insulation in construction like this, so again thank you. 👍🍻
It's worth knowing that poyurethane glues (gorilla glue original at least in this case) set with moisture. They can get that from the material or the air. XPS is very waterproof so moisture will not move out of the material. The glue foam itself is not waterproof so setting occurs through the material if it can't can moisture by any other route. Spraying the material so it is damp before glue application is generally a good idea when using polurathane glues on non-porous substrates. A lot of glues are strongly affected by whether the substrate is porous or not. Any glue that needs air/water to set and can't get it due to glueing two air/water-tight surfaces will not work well in that application. It's also true that the best glues are not these things with consumer-friendly names - they tend to be aimed at industry rather than DIY, and have 4-digit names, like bostik 2402, which is the best glue for neoprene. I don't actually know what's best for XPS. As you've found, a polurethane foam adhesive is pretty good. I would try a modified silane adhesive too (also moisture-setting) - which might have been what the construction adhesive you used was - sadly I am not familiar with the US brands you tested. e.g. Bostik P325 is a 2-part polyurethane adhesive designed for glueing frames to XPS which might be interesting to test.
You really got into this with a passion. Like I said I got a lot of studying to do but nice of you to act like Clift notes on the subject. Still have beers for you both and a parking space a mile from a dump station.
After watching the first two episodes of the foam bones build system I’m really impressed with both your system and your research. I’m off to watch the third; keep up the good content.
Some clean, creative, discrete, efficient, safe and ingenious methodology, technology and or features for the, storage, removal, disposal (even if via incineration) of black/waste/water and material should benefit many a fellow nomad.
As interesting as the first vol. was, I felt like I was watching a movie. It kept getting better and more intense as the 2nd vol. progressed. Brilliance in what you've done so far, peppered with humor. I'm binge watching here. What's next? Gotta go see!
When you're putting the gorilla glue into holes, decant the glue into a syringe and use that to put the glue in. You can see how much you're putting in and you can really get the nozzle into that hole!
THIS IS OUTSTANDING. I want to make a bigger bicycle camper and these ideas will lighten the load. I want to get started but I need more information ideas on lightening the load and to make it great looking and solid. The motorized bicycles these days are getting better and better. I love to go camping and the outdoors , but I have a heart problem and the physical gets in the way. so I need to be careful but not lazy. keep up the good work. Others can benefit from your ideas. Cheers :)
Some suggestions regarding glue application: Polyurethane is activated with moisture (Humidity). The other adhesives need the volatile solvents evaporated, so it helps to use a mastic spreader with fine notches to avoid excessive drying time. All of them should have pressure applied during the cure. Nice video Sir!
That's what I thought re Polyurethane glue. So perhaps spraying a water mist into the hole might improve expansion like it does with GreatStuff etc. With Greatstuff you can actually see how much misting helps when you compare areas that got misted vs not. In this case a perfume mister would be ideal@@falkornomad
Hey man, Just to let you know, I really like the long videos, and like super detailed stuff. So if you want to put out these nice long 40+ minute videos like this, by all means, I'm ALL for it!!! I'm watching all the way through, saving, liking, forwarding and suggesting, the whole 9 yards. Or, the whole X meters, depending on who's reading from where!
Awesome! I too prefer longer content for the DIY stuff. But honestly, producing them takes FOREVER and YT seems to prefer I do shorter more often rather than longer less often. My goal is to see it reach as many people as possibe (not satisfy the algorithm). But I clearly don’t know what I’m doing because the 50min video just exploded and the algorithm loves it… it’s all a mystery to me, lol Thanks for the feedback and for sharing!!
You're very welcome. I am trying to consider how to do a build in one of my two 2005 Dodge Grand Caravan minivans. What are you using for blocking out the light in the windows and windshield? I've been using those mylar solar silver "emergency blankets" in my house and they do well for reflecting A LOT of the visible and I think invisible heat spectrum back out. But they're not ideal for privacy entirely.
I actually took a short cut on those at the last minute… I had intentions of doing more with them but they are just reflectix cut to the shape… I left then a little tall for the door windows and close them in the doors. When not in use they go in the bed or in the dog bed depending on where the dogs are riding that day 🤷🏽♂️
Awesome work! Thank you for sharing! I watched every minute, and I'm sure others did too. Very informative on what to do, and not to do. I feel like using the screened panels would make it even stronger!
This is the best video I've watched in, what, months? Years? I used to dabble in laminated cardboard projects, but looking back, foam would work better for most of them. I am fully onboard with Gorilla Glue and have been since 1972 (before Gorilla Glue came on the market). The aerospace engineering department at my school built a homebuilt aircraft and the wing ribs were glued with PU glue. If I'm not too late to suggest one more glue to test, that would be E6000 used by hobbiests everywhere.\ Also the method you use to curve the foam is called kerfing.
👍 Nice job, Project Farm would be proud! You will definitely get more views with 20ish minute videos even if it means splitting a long one into 2 or more videos and releasing them even a day apart, just how it is.
Hi, great video’s. I like your down to earth style :). I got some experience with xps as a model-maker and we use 2component PU glue out of a ‘mixing-gun’ (maybe you know it already). It is an expensive glue but will perform similar to the expanded gorilla glue (i believe it is also PU glue, we have other name brands in EU). The advantage, for me, is that the 2-comp glue sets in one minute. So sometimes it is handy for build moments when there is no efficient way to support xps panels while drying. Like construction on the ceiling for example. Also, my dad used expanding foam in camper builds along with lightweight panels in the beginning of the 80’s. He got a bit carried away with the amount of foam :). But now, over time, these campers have rusty undersides and need to be welded. So we get burning foam. Very problematic. When i’m building my next van i’ll be using your great tips and tricks, but i’ll add some removable parts so i can weld safely (especially old VW vans ;) )
I know of 2part PU glues… gorilla original is a PU… I was looking to use easy to find, cheap and easy to use materials to make this method more accessible to diy builders. I think the consecutive is under utilized in diy builds. Good idea about removable… I had a modular concept for my prototype build in my VW van. 👍🏽
You just saved me a lot of time. Don't know why your videos hadn't come up weeks ago when searching XPS sandwich panels but so glad today was the day. Thank you
Awsome I've just stopped work due to health issues and have just started 2 builds, 1 a 43' MAN bus and the other a 2008 vito van. I'll be living permanently between the 2 and travelling Australia. Thankyou from a like minded person, I've found enjoyable informative youtube.
I don’t know what possessed you to go through all of this trouble, but I thank you. I’m getting ready to do my van and I’m going to use this method once I’m finished. I will be back to find out a way to donate some money to you.
You can tell this man is a intellectual he has a logical personality. In other words a very smart man with strong attention to details. Hes a mix between Spock from Star Trek and Bob Vila from This Old House. This man is Super smart handman/builder. Dont take this as Im poking fun or dissing you its meant as a compliment. Im saying your intelligent and a good builder your van is fantastic. You thought of everything so many multi functional parts. I like that its light weight and you combined insulation into thr structure so you dont have to mess with insulating then building its all done in the building materials. Question what is the cost to make one panel? Im trying to get a rough idea of cost. I would appreciate it if can give me the approx cost to make a 4x8 sheet the size of a sheet of ply. It would give me and idea of cost. Also I know you can use epoxy on foam board to make shower panels. You make a whole wet bath bathroom and you can paint it to look like marble or a acrylic pours or add shells, beads or whatever you want to the epoxy when its dry whatever you use to add to the look of the epoxy foam panels its not coming a part its stuck in the epoxy forever and its water proof. Ive also seen foam and expoxy as counter tops and they look beautiful. Now that I know you can actually build with foam and it can be made into a strong building material. Im going to be trying it out when building out my short school bus. I love this Idea of foam Skoolies can use all the extra insulation they can get skoolies are not known to be well insulated they are cooled in the winter and hot in the summer if not well insulated so I think this type of build would be very good for a skoolie. Plus being a women This maybe easier for me to do by myself. Carrying and holding sheets of plywood in place while trying to screw it down isnt easy and its heavy. Plus this looks a little more forgivable then cutting a 30 to 50 dollar sheet of ply and screwing it up is a costly mistake. Anyways Thanks for all the good info. I enjoyes watching
Man, I like your content. Please don't stop content. It is content, not all real. You are pretty real, like the cargo video. Dude, keep it up and do more.
If the insert is placed in the wrong spot (say it's 1/8" off where it HAS to be for a drawer slide or something) what's your preferred way of fixing the goof? Fixing, repairing, and/or modifying a "finished" foam build might be worth a video all it's own.
That video is in the works right now. I am actually doing some fixes or changes like that right now in the van. It is more challenging for small (1/8” off) changes. If all else fails you can cut a section of the foam out and glue a new piece in. I would do this with the finger joints to get more surface area and screen over the joint / seam. If you have a failure… say the anchor pulls out and brings foam with it… you can glue that same anchor (with glue and foam) back in with the Gorilla original or Gorilla HD construction adhesive. Or you can add a new anchor in to that hole with the HD construction adhesive. The strength will not be as much but it’s still strong.
I'd suggest applying a thin film of glue over the entire mating surfaces of both pieces before putting them together. If you make thin coats, there won't be any movement between the two surfaces. Making the bond stronger. Believe it or not. Less is more. You'll get the strongest bond from the thinnest coats. As long as you mate the two surfaces before the glue starts to dry.
Hey there. Again, i like your take on using foam. And im amazed with the outcome of gorilla glue. So thanks for this content. I suggest to use thin metal plates, like 2 inch x 2 inch and mount a rivet nut on that plate. And laminate this plate with rivet nut on the surface of the foam. This is commonly done with fiberglass composites. Perhaps this could also work with poor man fiberglass. The idea is that with this technique you increase the surface on where bolts, or screws needs to pull force on.
Yeah, that would work, even larger diameter washers can be used. This approach takes more planning to know where you need washers on both sides of foam. While the screw anchors can be done at any time. Good tip though!
Awesome video and very well approached testing. I use the green foam board, (no score marks in the thicker panels), to make yard decorations for Halloween and Christmas and have always used the original Gorilla Glue with excellent results. I do dampen one surface of glue up and clamp or weight it down where ever possible. One trick I’ve learned is when it foams up and has dried for an hour or so, (before it’s fully cured), the excess foam can easily be trimmed off with a razor knife or equivalent. I’m super impressed with the plastic screw in anchors you used and will be incorporating those into any future builds. Well done sir, keep us educated with your knowledge. 👍🏻👍🏻
Super Cool! I'd never have guessed you could get that much holding power with foam and glue. The anchor test blew my mind! This video series has a lot of value for anyone building anything: van, bus, or any other type of thing where foam board is an option. Much appreciated!
I eventually found the time to sit through your first two videos. Great work and the most thorough research and the best demonstrations I've seen on UA-cam. Thank you.
This resolved a lot of my questions. I'm very impressed with your use of spiral inserts with glue - that worked FAR better than I thought. Most urethane glues have another advantage, too. If they get wet, the urethane re-activates and the bond self-heals.
@@falkornomad I was not surprised. Back in the 70s when I was an aerospace student, our department built a Baby Ace airplane. The wing ribs were glued together with the 1971 equivalent of Gorilla Glue. The PU glue joint is easily stronger than the substrate.
I watched the first vid. I decided to binge watch the rest. This series is one of the best quality videos on UA-cam. A thought to consider: Gorilla original is brittle, but very stiff. If you wanted to reenforce a panel, could you punch holes in the center of the "edge" of the panel and then fill with the glue? ( Think rebar in cement )
Really appreciate all the details. We’re in the beginnings of our van build(stripped down, about to build cabinets/furniture) and this made me think twice about how we’re gonna get it done. Great idea man!
Absolutely shocked by these results. I work with carbon fibre and fibreglass (boat and glider design & repair in my free time) and one thing that was ingrained in me early on by instructors was: always design in a harder, load bearing material for sections requiring fittings like bolts or screws…seeing these numbers just on straight foam & glue is jaw-dropping. I personally still would screw straight into foam unless it was something with low loading (like a cupboard door for example) but still, it goes to show how tough these materials and glues really are. Thank you very much for sharing! Subscribed! ❤️
I am shocked ..😲. 80lbs force plus for anchor screws in foam !!!! This is nuts. This now changes one of my project's plan I have been developing new techniques for building hex domes, for storage, growing and living accomodation. I mean 25 feet high 50 feet wide domes. I had planned to use pallet wood, and form them into H beams to give them extra strength. But your foam bones structures have impressed me so much. I was looking at using nail guns , mitre saws, custom built jigs and templates to streamline the operation. Now i'm thinking ..' foam sandwiches ' 🤔.... They would be lighter, easier to erect the sections. If i wanted to resite the completed dome frame a dozen people could probably lift it. Then there's the cladding. Foam panels with sheet glued into place NO SCREWS or nails. The more i think about it the more doable it seems. Plus internal stairs, bulk heads, kitchen and bath fittings ... everything made from foam sandwiches . This is a revolution These are the homes of the future. No more styrofoam land infill. 😮
That sounds amazing, keep me posted as you test it out!! My prototype build was a single sink cabinet… think nightstand or small bathroom vanity size… it was 15# with a stainless top and a diamond plated aluminum kick plate. So while I’m not sure a single person could lift a dome that size, quite possibly 4 people.
@@falkornomad - thank you for your reply and encouragement, much appreciated. Yes the prospect of a small number of people moving big structures into place is quite exciting. It keeps me awake at night. Some recent developments in diy recycling of acrylic and scrap polystyrene offers some interesting opportunities also the use of carbon cloth. I am now meditating on a total new approach. Instead of recycling scrap wood I am thinking of scrap plastics and other land infill materials. Even some of the latest developments of cheap hemp fibre and 3D printing on a grander scale is opening up fresh perspectives for the future. We live in fascinating times.
So glad i found out about you. This will be so beneficial to apply your knowledge to my tear drop trailer that i am soon to build. I will be pulling behind my road glide. Thanks✊
Excellent information! Love the thinking outside the box ... I'm all about alternative building methods and materials... ths in my opinion is how mankind advances
excellent content!! I'll be parusing your channel before I know if i have questions, but I'm beginning to convert my car and having a blast, so I'm so glad you exist!❤
I know some RV manufacturers put EGS (Electro Galvanized Steel) where they secure cabinets, awnings, etc, onto laminated walls. (There is white foam between layers of luan and fiberglass in many RV laminated walls.) EGS is super thin and it is very easy to over-torque a screw. If I get the chance to do a pull test (recreate what you did) I'd like to know how well a screw holds in EGS vs glue. Was glad to see episode #2 pop up in my feed -- and YES!!! -- shorter and more often, please. :)
I think it would be great for that! The XPS is also mold and mildew resistant. AND float homes have less vibration and bumps when driving down the road!!
I trusted gorilla super glue and their tape but I did not know this particular gorilla glue was just as good now that's going on my list when I start my build out
The thing with original gorilla glue is it’s designed to set up with water. So if you take a damp cloth and wipe down whatever you’re gluing it will set up faster, stronger, and less brittle around the edges. The other thing I thought of is the layer of mesh and adhesive you used on the foam board you put the slides on added even more staying power to keep those screw anchors in place. It would be interesting to see a pull test where you had the mesh on already, and the foam on foam where you wet down the foam first with a damp cloth and compare them to the fist pull test. You could even dampen the plastic screw anchor by dipping it into some water before screwing it into the hole filled with the glue and see how that works.
Really enjoying this content, def gonna watch the whole series. Watching the foam testing without your face, you sound a good bit like Nic Cage lol subbed
The foam anchor failure video is up next, then glue up and screen video… in that one I briefly cover how I add the anchors for the 1/2” ply I have as cabinet faces, then the next video is skinning of foam with 1/8” ply, carpet, veneer, etc. That all said, normally I am gluing the 1/8” ply to the foam with the gorilla glue HD construction adhesive and clamping it down to dry.
This is awesome man, I really appreciate your efforts in the experiments!!! This will help me tremendously as I embark in my van build journey hopefully soon. For safety's sake, please wear protective goggles next time.
In situations like that it might be worth retesting one or two candidates. You have a baseline measurement for each one, so repeating the test in triplicate for them will give you a solid understanding of how much those measurements can vary.
This retired R&D scientist appreciates your systematic approach to this. Reminds me of being in the lab again.
Forget building a van with this, I'm buliding my house like this.
Use foam board with wire mesh and grout for home building. Pull wires through the foam board to tie the mesh to both sides of the foam board. Use great stuff spray foam to glue your joints together. Use any cementitious mixture to coat the wire lath to make a house. Use foam backed corrugated metal panels for the roof. It will not comply with local building codes because the government does not want you to escape their system.
Fire?
IKR? lol
That's what I was thinking
@@darylblack196 Stucco, Aircrete, might be good Surfaces to use over the Foam Basics! For Fireproofing, anyway!
Thanks man. You literally save so many people from wasting time and money with these tests. We appreciate all you've done.
My pleasure!
That's what I was going to say!! 😊
👍🏽👍🏽👍🏽
@@falkornomadthanks for showing us why and how. Not just saying use this. Great research brother!
Yes!
I personally prefer high quality authentic content regardless of length.
👍🏽
Thank you for making this series. There is So Much Value in moving from anecdotes about products and methods to actual testing and results!
My pleasure 👍🏽
Use GREAT STUFF spray foam to bond foam board.
You have saved a builder, I'll bet close to 100 hours of testing with the glue and screw anchor styles, thanks.
I like the scientific approach you take to testing different properties of materials.
Thanks! 👍🏽
Hey man, I appreciate the work you put into these videos, but I do have a few tips from my own testing on a similar project:
1- a larger sample size would improve the accuracy of the results, i.e. 2 or 3 tests of each glue/insert combination.
2- I recommend trying great stuff expanding foam! They also have a great stuff "construction adhesive" that applies with a foam gun and bonds as well or better than gorilla caulk adhesive! Also far less messy than the canned foam, and cuts with a hot knife blade far easier.
3- a Stanley "surfform" rasp/plane works amazingly well for shaving foam to shape (it's what they use to make surfboards), though dusty.
4- buy some Bosch "soft material" jigsaw blades! They have a wavy looking knife edge, model T313AW, that I've grown to prefer over anything else since they're not as dusty as a utility knife, cleaner cut than a circular saw, and no fumes like a hot knife!
Thanks again for the work you put into these videos, it inspired me to tackle the biggest project of my life, a tiny home made entirely out of foam, and likely inspired countless others. I eventually plan on making plans/blueprints for others to follow, and instructional videos as well.
None of this would have happened without you, so thanks again for putting this information out in the world. Peace and love!
One more thing,
I've had great luck painting the fiberglass screen material on a whole 4x8 sheet, then cutting to shape with the jigsaw. It takes more planning to not waste material, but if you have the dimensions down ahead of time and shave to adjust fit with the surfform, its a HUGE timesaver.
Then I puzzle-piece them together like you, and glue with great stuff foam and drywall screws to hold while it dries.
Great tips and SO great to hear I inspired you and gave you info to tackle such a big project!! That’s the main reason I made these videos to start with! It means a great deal to me to hear stories like this! Would love to see your project!
Rad, good idea!
@@falkornomad I will definitely cite you as inspiration when I get around to making a video! Trying to finish in time for Burning Man this year.
One question, do you sand or otherwise prepare the shiny, slick surface or the foam before painting? I've found it improves adhesion, but sanding dramatically increases labor time, and I was wondering if you found a faster way. I also heard rubbing alcohol dissolves the "skin" but haven't tried it yet.
I have been asked this previously and I have not noticed a shiny side… it was described to me a a physical coating that could be peeled off? Maybe the newer xps has this on it?? I have never treated the foam prior to glue or screening at all. That said, either way maybe a test is in order glue two shiny sides together and two sanded sides and see what you get. Let me know. Next time I’m in a hardware store I’ll see if it’s something new. Is it on both sides or just the side with the black printing on it?
♥the "project farm" style tests! I was glued to my screen for 27 minutes - SOLID. I will watch whatever length video you post. don't care about yt algorithms.
Glad you liked it! I try not to care about YT algorithms… but in an effort to get the info out to more viewers I’m realizing I have to. I prefer watching longer videos if it’s something I really want to know about, however it is easier to produce shorter videos. And since I never know how good my internet connection will be, uploading smaller videos is MUCH easier.
Men built the world And discover the principles of investment...... You are a perfect example of the builders.
Wish I had found these earlier today, now I will be up all night watching them I am hooked!
Thank you for the thorough ,informative ,no bullshit results. You come off as an intelligent ,interesting ,and show just how much baloney we eat each day while staring at the screen.I am a retired building trades guy from the city of Boston so I believe I can pick up on the real deal
Thanks, that’s a nice compliment and I appreciate you taking the time to write it!
I'm finding this so ridiculously interesting! I'm nearly done with my build and I wish I had learned about this sooner. Thanks for showing us these tests, it must have taken a lot of time & expense to find the best one.
There’s always the next build 😜 You’re welcome, actually the testing was not much work… the editing and narration is the most work!
This guy needs to go viral!
You should inspect a hollow core interior door, like the old birch doors. They inserted a wood strip or blocks at the edge of the doors for mounting hardware but the door is a cardboard honeycomb in the center. You could probably do that with the foam without adding much weight. Makes a cleaner edge for front of cabinets and adds strength for screws. Just a thought…. I like the foam interlocking panels. Nice job!
Thanks for your very detailed comparison of glueing and screwing foam boards inspires me for this material selection for a light weight bicycle trailor with good thermal insulation!
It would be great for that!!
You have really good intentions when it comes to teaching others about what you have come across. Good ideas.
Thanks! I appreciate that you get that vibe… it’s true I do have good intentions
I'm so grateful to you and quite admirable of your fraternal and amicable virtues, even beyond your diligence.
Your ideas, methods, research is off the chain impressive!
I'll watch what ever length video you chose. I'm just so thankful, impressed!! I had been thinking about using this insulation board but you bumped it up many levels! I love your brain!!!
Thanks! Glad you enjoyed it! I like my 🧠 too… but I don’t have anything to compare it to I guess 😉
Just saw both videos on this. Thank you very much. You just saved me time and, most importantly, MONEY! I always wondered about ridged insulation in construction like this, so again thank you. 👍🍻
my pleasure... there are many videos on the channel about this build system and more to come.
It's worth knowing that poyurethane glues (gorilla glue original at least in this case) set with moisture. They can get that from the material or the air. XPS is very waterproof so moisture will not move out of the material. The glue foam itself is not waterproof so setting occurs through the material if it can't can moisture by any other route. Spraying the material so it is damp before glue application is generally a good idea when using polurathane glues on non-porous substrates. A lot of glues are strongly affected by whether the substrate is porous or not. Any glue that needs air/water to set and can't get it due to glueing two air/water-tight surfaces will not work well in that application.
It's also true that the best glues are not these things with consumer-friendly names - they tend to be aimed at industry rather than DIY, and have 4-digit names, like bostik 2402, which is the best glue for neoprene. I don't actually know what's best for XPS. As you've found, a polurethane foam adhesive is pretty good. I would try a modified silane adhesive too (also moisture-setting) - which might have been what the construction adhesive you used was - sadly I am not familiar with the US brands you tested. e.g. Bostik P325 is a 2-part polyurethane adhesive designed for glueing frames to XPS which might be interesting to test.
Thanks… I realized that later and definitely should have done that for these tests and my build!
Awesome. Thanks for all your time invested. You saved me a lot of questions. Especially the screw mounts. 🎉❤
You really got into this with a passion. Like I said I got a lot of studying to do but nice of you to act like Clift notes on the subject. Still have beers for you both and a parking space a mile from a dump station.
👍🏽🍻
After watching the first two episodes of the foam bones build system I’m really impressed with both your system and your research. I’m off to watch the third; keep up the good content.
Thanks!!
Some clean, creative, discrete, efficient, safe and ingenious methodology, technology and or features for the, storage, removal, disposal (even if via incineration) of black/waste/water and material should benefit many a fellow nomad.
As interesting as the first vol. was, I felt like I was watching a movie. It kept getting better and more intense as the 2nd vol. progressed. Brilliance in what you've done so far, peppered with humor. I'm binge watching here. What's next? Gotta go see!
Binge Away! Don’t miss the StarWars interludes on the Electrical playlist!
When you're putting the gorilla glue into holes, decant the glue into a syringe and use that to put the glue in. You can see how much you're putting in and you can really get the nozzle into that hole!
I was amazed at the pull-out Strength of the anchors. Excellent info, thanks.
My pleasure!
THIS IS OUTSTANDING. I want to make a bigger bicycle camper and these ideas will lighten the load. I want to get started but I need more information ideas on lightening the load and to make it great looking and solid. The motorized bicycles these days are getting better and better. I love to go camping and the outdoors , but I have a heart problem and the physical gets in the way. so I need to be careful but not lazy. keep up the good work. Others can benefit from your ideas. Cheers :)
Some suggestions regarding glue application: Polyurethane is activated with moisture (Humidity). The other adhesives need the volatile solvents evaporated, so it helps to use a mastic spreader with fine notches to avoid excessive drying time. All of them should have pressure applied during the cure.
Nice video Sir!
👍🏽
That's what I thought re Polyurethane glue. So perhaps spraying a water mist into the hole might improve expansion like it does with GreatStuff etc. With Greatstuff you can actually see how much misting helps when you compare areas that got misted vs not. In this case a perfume mister would be ideal@@falkornomad
Great demonstration on Anchors Glue Test And Strength . Great video on Explaining Everything in Detail. Thks for Sharing. Very Interesting !!!!
Thank you! More to come!
Hey man, Just to let you know, I really like the long videos, and like super detailed stuff. So if you want to put out these nice long 40+ minute videos like this, by all means, I'm ALL for it!!! I'm watching all the way through, saving, liking, forwarding and suggesting, the whole 9 yards. Or, the whole X meters, depending on who's reading from where!
Awesome! I too prefer longer content for the DIY stuff. But honestly, producing them takes FOREVER and YT seems to prefer I do shorter more often rather than longer less often. My goal is to see it reach as many people as possibe (not satisfy the algorithm). But I clearly don’t know what I’m doing because the 50min video just exploded and the algorithm loves it… it’s all a mystery to me, lol
Thanks for the feedback and for sharing!!
You're very welcome.
I am trying to consider how to do a build in one of my two 2005 Dodge Grand Caravan minivans.
What are you using for blocking out the light in the windows and windshield? I've been using those mylar solar silver "emergency blankets" in my house and they do well for reflecting A LOT of the visible and I think invisible heat spectrum back out. But they're not ideal for privacy entirely.
I actually took a short cut on those at the last minute… I had intentions of doing more with them but they are just reflectix cut to the shape… I left then a little tall for the door windows and close them in the doors. When not in use they go in the bed or in the dog bed depending on where the dogs are riding that day 🤷🏽♂️
Awesome work! Thank you for sharing! I watched every minute, and I'm sure others did too. Very informative on what to do, and not to do. I feel like using the screened panels would make it even stronger!
True, adding screen would make the pull out strength higher… if you added canvas even higher… add 1/8” ply even more, etc.
This is a great series of videos. Thanks for doing the investigative work for the rest of us.
This is the best video I've watched in, what, months? Years? I used to dabble in laminated cardboard projects, but looking back, foam would work better for most of them.
I am fully onboard with Gorilla Glue and have been since 1972 (before Gorilla Glue came on the market). The aerospace engineering department at my school built a homebuilt aircraft and the wing ribs were glued with PU glue.
If I'm not too late to suggest one more glue to test, that would be E6000 used by hobbiests everywhere.\
Also the method you use to curve the foam is called kerfing.
👍 Nice job, Project Farm would be proud! You will definitely get more views with 20ish minute videos even if it means splitting a long one into 2 or more videos and releasing them even a day apart, just how it is.
That’s the new strategy… weekly sub 20min
Wow. This a a graduate level degree in Van Build.
Thanks!
You have amazing research and teaching talents.
Hi, great video’s. I like your down to earth style :). I got some experience with xps as a model-maker and we use 2component PU glue out of a ‘mixing-gun’ (maybe you know it already). It is an expensive glue but will perform similar to the expanded gorilla glue (i believe it is also PU glue, we have other name brands in EU). The advantage, for me, is that the 2-comp glue sets in one minute. So sometimes it is handy for build moments when there is no efficient way to support xps panels while drying. Like construction on the ceiling for example. Also, my dad used expanding foam in camper builds along with lightweight panels in the beginning of the 80’s. He got a bit carried away with the amount of foam :). But now, over time, these campers have rusty undersides and need to be welded. So we get burning foam. Very problematic. When i’m building my next van i’ll be using your great tips and tricks, but i’ll add some removable parts so i can weld safely (especially old VW vans ;) )
I know of 2part PU glues… gorilla original is a PU… I was looking to use easy to find, cheap and easy to use materials to make this method more accessible to diy builders. I think the consecutive is under utilized in diy builds. Good idea about removable… I had a modular concept for my prototype build in my VW van. 👍🏽
Thank you so much !! My camper leaked and going to gut it due to the order and this is how I want to remold it. Thanks again.
You just saved me a lot of time. Don't know why your videos hadn't come up weeks ago when searching XPS sandwich panels but so glad today was the day. Thank you
Well that’s a search term I don’t use… good point… I’m a poor YT’er lol
Awsome I've just stopped work due to health issues and have just started 2 builds, 1 a 43' MAN bus and the other a 2008 vito van. I'll be living permanently between the 2 and travelling Australia. Thankyou from a like minded person, I've found enjoyable informative youtube.
Awsome vids, that I can watch the whole way through without losing interest, or calling BS is a big thumbs up from me.
ps. ❤️your Transporter shirt.
I don’t know what possessed you to go through all of this trouble, but I thank you. I’m getting ready to do my van and I’m going to use this method once I’m finished. I will be back to find out a way to donate some money to you.
The tests you do to find the best materials and methods are useful to shorten learning curves. Thank you!
That is only true for everyone ELSE’s learning curves, lol… longer for mine… but worth it! Cheers 🍻
interesting, i started making a vardo wagon, this makes me want to change the design
Lots of potential imo, but, to be fair I’m only 5 years into the prototype and 7mo into the full Transit build… so still “experimental”
Love these videos! Although they are a LOT easier for my brain to watch at 1.5x speed
Thank you. Your information is rather helpful.
You can tell this man is a intellectual he has a logical personality. In other words a very smart man with strong attention to details. Hes a mix between Spock from Star Trek and Bob Vila from This Old House.
This man is Super smart handman/builder. Dont take this as Im poking fun or dissing you its meant as a compliment. Im saying your intelligent and a good builder your van is fantastic. You thought of everything so many multi functional parts. I like that its light weight and you combined insulation into thr structure so you dont have to mess with insulating then building its all done in the building materials.
Question what is the cost to make one panel? Im trying to get a rough idea of cost.
I would appreciate it if can give me the approx cost to make a 4x8 sheet the size of a sheet of ply. It would give me and idea of cost.
Also I know you can use epoxy on foam board to make shower panels. You make a whole wet bath bathroom and you can paint it to look like marble or a acrylic pours or add shells, beads or whatever you want to the epoxy when its dry whatever you use to add to the look of the epoxy foam panels its not coming a part its stuck in the epoxy forever and its water proof.
Ive also seen foam and expoxy as counter tops and they look beautiful.
Now that I know you can actually build with foam and it can be made into a strong building material. Im going to be trying it out when building out my short school bus.
I love this Idea of foam Skoolies can use all the extra insulation they can get skoolies are not known to be well insulated they are cooled in the winter and hot in the summer if not well insulated so I think this type of build would be very good for a skoolie.
Plus being a women This maybe easier for me to do by myself. Carrying and holding sheets of plywood in place while trying to screw it down isnt easy and its heavy.
Plus this looks a little more forgivable then cutting a 30 to 50 dollar sheet of ply and screwing it up is a costly mistake.
Anyways Thanks for all the good info. I enjoyes watching
I am impressed with the painstaking effort you put i to showing all of us!!! THANK YOU! I'm doing it!
Good luck! Keep me posted!!
Man, I like your content. Please don't stop content. It is content, not all real. You are pretty real, like the cargo video. Dude, keep it up and do more.
If the insert is placed in the wrong spot (say it's 1/8" off where it HAS to be for a drawer slide or something) what's your preferred way of fixing the goof? Fixing, repairing, and/or modifying a "finished" foam build might be worth a video all it's own.
That video is in the works right now. I am actually doing some fixes or changes like that right now in the van. It is more challenging for small (1/8” off) changes. If all else fails you can cut a section of the foam out and glue a new piece in. I would do this with the finger joints to get more surface area and screen over the joint / seam. If you have a failure… say the anchor pulls out and brings foam with it… you can glue that same anchor (with glue and foam) back in with the Gorilla original or Gorilla HD construction adhesive. Or you can add a new anchor in to that hole with the HD construction adhesive. The strength will not be as much but it’s still strong.
I'd suggest applying a thin film of glue over the entire mating surfaces of both pieces before putting them together.
If you make thin coats, there won't be any movement between the two surfaces. Making the bond stronger.
Believe it or not. Less is more.
You'll get the strongest bond from the thinnest coats. As long as you mate the two surfaces before the glue starts to dry.
I don't have plans to build anything, but still found this interesting.
Hey there. Again, i like your take on using foam. And im amazed with the outcome of gorilla glue. So thanks for this content. I suggest to use thin metal plates, like 2 inch x 2 inch and mount a rivet nut on that plate. And laminate this plate with rivet nut on the surface of the foam. This is commonly done with fiberglass composites. Perhaps this could also work with poor man fiberglass. The idea is that with this technique you increase the surface on where bolts, or screws needs to pull force on.
Yeah, that would work, even larger diameter washers can be used. This approach takes more planning to know where you need washers on both sides of foam. While the screw anchors can be done at any time. Good tip though!
Awesome video and very well approached testing. I use the green foam board, (no score marks in the thicker panels), to make yard decorations for Halloween and Christmas and have always used the original Gorilla Glue with excellent results. I do dampen one surface of glue up and clamp or weight it down where ever possible. One trick I’ve learned is when it foams up and has dried for an hour or so, (before it’s fully cured), the excess foam can easily be trimmed off with a razor knife or equivalent. I’m super impressed with the plastic screw in anchors you used and will be incorporating those into any future builds. Well done sir, keep us educated with your knowledge. 👍🏻👍🏻
Super Cool! I'd never have guessed you could get that much holding power with foam and glue. The anchor test blew my mind! This video series has a lot of value for anyone building anything: van, bus, or any other type of thing where foam board is an option. Much appreciated!
Blew my mind too… that reaction face is no act, this was all shot real time, first time. Glad it was helpful, that’s the only reason I make these!🍻
I eventually found the time to sit through your first two videos. Great work and the most thorough research and the best demonstrations I've seen on UA-cam. Thank you.
Thanks for finding and making the time, glad it was worth it!!!
This resolved a lot of my questions. I'm very impressed with your use of spiral inserts with glue - that worked FAR better than I thought. Most urethane glues have another advantage, too. If they get wet, the urethane re-activates and the bond self-heals.
I was surprised as well!!!
@@falkornomad I was not surprised. Back in the 70s when I was an aerospace student, our department built a Baby Ace airplane. The wing ribs were glued together with the 1971 equivalent of Gorilla Glue. The PU glue joint is easily stronger than the substrate.
I watched the first vid. I decided to binge watch the rest. This series is one of the best quality videos on UA-cam.
A thought to consider: Gorilla original is brittle, but very stiff. If you wanted to reenforce a panel, could you punch holes in the center of the "edge" of the panel and then fill with the glue? ( Think rebar in cement )
Clever idea… lots of work but clever! Thanks for the compliment!!
Fantastic job on the practical tests... good enough. The results speak for themselves, and I appreciate your approach. Thank you!!
My pleasure👍🏽
Really appreciate all the details. We’re in the beginnings of our van build(stripped down, about to build cabinets/furniture) and this made me think twice about how we’re gonna get it done. Great idea man!
FYI, There’s a whole series around that video if you didn’t notice. Glad it was helpful, you’re welcome!
Great job 👏 Thanks 👍
👍🏽
Thank you for doing all this work for us!
Absolutely shocked by these results. I work with carbon fibre and fibreglass (boat and glider design & repair in my free time) and one thing that was ingrained in me early on by instructors was: always design in a harder, load bearing material for sections requiring fittings like bolts or screws…seeing these numbers just on straight foam & glue is jaw-dropping. I personally still would screw straight into foam unless it was something with low loading (like a cupboard door for example) but still, it goes to show how tough these materials and glues really are.
Thank you very much for sharing! Subscribed! ❤️
that info was very useful. saves me the time and cost of testing myself. thanx!
👍🏽
Subbed. This information is wonderful. Thank you for your rigorous testing. Your videos are very well put together. Great stuff!
Thanks! Especially for the “well put together” part… I’m rocking a 2 iPhones and a microphone studio set up here so glad they end up watchable!!
These are great. I appreciate your thoroughness. I've long been an advocate in tab-and-slot design for assemblies. Keep up the good work!
I am shocked ..😲. 80lbs force plus for anchor screws in foam !!!!
This is nuts.
This now changes one of my project's plan
I have been developing new techniques for building hex domes, for storage, growing and living accomodation.
I mean 25 feet high 50 feet wide domes.
I had planned to use pallet wood, and form them into H beams to give them extra strength.
But your foam bones structures have impressed me so much.
I was looking at using nail guns , mitre saws, custom built jigs and templates to streamline the operation.
Now i'm thinking ..' foam sandwiches ' 🤔....
They would be lighter, easier to erect the sections.
If i wanted to resite the completed dome frame a dozen people could probably lift it.
Then there's the cladding.
Foam panels with sheet glued into place NO SCREWS or nails.
The more i think about it the more doable it seems.
Plus internal stairs, bulk heads, kitchen and bath fittings ... everything made from foam sandwiches .
This is a revolution
These are the homes of the future.
No more styrofoam land infill.
😮
That sounds amazing, keep me posted as you test it out!! My prototype build was a single sink cabinet… think nightstand or small bathroom vanity size… it was 15# with a stainless top and a diamond plated aluminum kick plate. So while I’m not sure a single person could lift a dome that size, quite possibly 4 people.
@@falkornomad - thank you for your reply and encouragement, much appreciated. Yes the prospect of a small number of people moving big structures into place is quite exciting.
It keeps me awake at night.
Some recent developments in diy recycling of acrylic and scrap polystyrene offers some interesting opportunities also the use of carbon cloth. I am now meditating on a total new approach. Instead of recycling scrap wood I am thinking of scrap plastics and other land infill materials.
Even some of the latest developments of cheap hemp fibre and 3D printing on a grander scale is opening up fresh perspectives for the future.
We live in fascinating times.
Thanks for the detailed process and thorough explanation of your content. 😎👍👍
Love your attention to detail - massively helpful!
So glad i found out about you. This will be so beneficial to apply your knowledge to my tear drop trailer that i am soon to build. I will be pulling behind my road glide. Thanks✊
Rad, glad you found it… or… it found you… either way, welcome aboard and good luck!
This is really cool for people is already living in a van and don’t have a place to cut wood
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Great testing! Your extra time and work saves everyone else a lot of hassle and money! Awesome job!
Excellent information! Love the thinking outside the box ... I'm all about alternative building methods and materials... ths in my opinion is how mankind advances
I like your enthusiasm, I really dig the experiments that you're doing
excellent content!! I'll be parusing your channel before I know if i have questions, but I'm beginning to convert my car and having a blast, so I'm so glad you exist!❤
Thanks! I too am glad I exist!! 😜
I keep coming back to watch your videos. So good.
I appreciate your testing regimen.
Is that a storm trooper avatar?!? You have to watch my electrical playlist and give me feed back on my starwars interludes!! Lol
I know some RV manufacturers put EGS (Electro Galvanized Steel) where they secure cabinets, awnings, etc, onto laminated walls. (There is white foam between layers of luan and fiberglass in many RV laminated walls.) EGS is super thin and it is very easy to over-torque a screw. If I get the chance to do a pull test (recreate what you did) I'd like to know how well a screw holds in EGS vs glue. Was glad to see episode #2 pop up in my feed -- and YES!!! -- shorter and more often, please. :)
Yeah, test that out and let me know!
Going to use this in a float home build.
I think it would be great for that! The XPS is also mold and mildew resistant. AND float homes have less vibration and bumps when driving down the road!!
I trusted gorilla super glue and their tape but I did not know this particular gorilla glue was just as good now that's going on my list when I start my build out
Your videos are great, thank you for being so in-depth with the testing. This will safe me time and effort in building mine square drop trailer.
You’re an absolute legend for this! Thank you!!
Always wondered which glue was better. Now we have a really good idea! Ty
Wow, incredible amount of work, and comprehensive analysis, for this video, Kudos!
Thanks
Very interesting results. They really demystify all the marketing hype and materials. Thanks very much. Looking forward to the next video.
👍🏽
You really took one for the team; thanks for putting together and sharing this excellent vid.
Thanks! Your welcome!
Place a piece of blue painter tape on the board before squeeze grilla glue.
After glue set, pell off the tape will give a clean surface.
Love this channel so glad i found it. A side note: you looknlike the bad guy in the movie HEAT that was holed up in the hotel.
Glad you enjoy it! I guess with enough beard and long hair all white dudes look the same.
Really top notch. Your design skill is excellent and the finish is awesome. Cool.
The thing with original gorilla glue is it’s designed to set up with water. So if you take a damp cloth and wipe down whatever you’re gluing it will set up faster, stronger, and less brittle around the edges. The other thing I thought of is the layer of mesh and adhesive you used on the foam board you put the slides on added even more staying power to keep those screw anchors in place. It would be interesting to see a pull test where you had the mesh on already, and the foam on foam where you wet down the foam first with a damp cloth and compare them to the fist pull test. You could even dampen the plastic screw anchor by dipping it into some water before screwing it into the hole filled with the glue and see how that works.
That was a dumb oversight on my part! I know it should be damp and just forgot when I turned on the camera 🤷🏽♂️
Really enjoying this content, def gonna watch the whole series. Watching the foam testing without your face, you sound a good bit like Nic Cage lol subbed
Hu… like Outsiders or Raising Arizona, or more recent stuff? HOW OLD DO I SOUND?!?!? Lol
Glad you enjoy the content.. much more to come!
This is a great idea and series of videos. Can you show us how to attach the ply to the foam plz!
The foam anchor failure video is up next, then glue up and screen video… in that one I briefly cover how I add the anchors for the 1/2” ply I have as cabinet faces, then the next video is skinning of foam with 1/8” ply, carpet, veneer, etc.
That all said, normally I am gluing the 1/8” ply to the foam with the gorilla glue HD construction adhesive and clamping it down to dry.
Those are some quite impressive results for foam and glue. Sure exceeded my expectations.
Mine too my friend, mine too!
Great job man.
I'm an old geezer tinkering in the backyard. Dreaming of that perfect van build.
27:02
Glad you enjoyed it!
Dude! Great job! Getting the idea to build a removable gypsy wagon camper for my utility trailer. Your videos are an invaluable source.
Rad! Keep me posted on how that goes!!
This is awesome man, I really appreciate your efforts in the experiments!!! This will help me tremendously as I embark in my van build journey hopefully soon. For safety's sake, please wear protective goggles next time.
A thanks again for the effort save everyone a lot of worry
In situations like that it might be worth retesting one or two candidates. You have a baseline measurement for each one, so repeating the test in triplicate for them will give you a solid understanding of how much those measurements can vary.
I actually plan to do a follow up at some point and use this approach, thanks.
@@falkornomad 👍🏻