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Old 09-23-2014, 12:47 AM   #162 (permalink)
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Join Date: Apr 2011
Location: Tacoma WA
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Woody - '96 Dodge Ram 2500 SLT
Team Cummins
90 day: 23.82 mpg (US)

Avion and Woody - '96 Dodge/Avion Ram 2500/5th wheel combo
90 day: 15.1 mpg (US)

TD eye eye eye - '03 Volkswagen Beetle GLS
90 day: 49.05 mpg (US)

Mule - '07 Dodge Ram 3500 ST
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Originally Posted by jray3 View Post
I'd like to build a trailer shell following the template, but with flat panels that are precut to shape, zeppelin-style. Undecided on a riveted aluminum skin vs foam panels to then glass over, or soaking an inflated envelope with resin, then building it up, but am leaning towards aluminum (possibly with a spray-foam interior layer to stiffen and insulate).
So far I've struck out on finding a pattern to scale up. Closest thing is these hot air balloon panels from a crafter's blog (don't laugh if you click through).

DIY Hot Air Balloon Mobile (Free Pattern!) | Pretty Prudent

This company gets me close, have requested a design cost estimate....
APEX Balloons - Hot Air Balloon Manufacturer, Hot Air Airships, Balloon Repair Station

Any of you design wizards already cracked this nut?
Graham, eh?
Maybe we need to get together and do some brainstorming. I too have a trailer or two stuck in my brain; my medium is probably going to be XPS foam, shaped and then glass/epoxy.

2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
Custom cab, auto, 3.55 gears
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