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skyking · 08-02-2015, 11:22 AM

I mentioned some house remodel and truck mods to do first, what 3 years ago?
I have a different truck that needs a cleanup, and I have touched every room in the house now. I am finishing up the kitchen in the next weeks so that will be done.
Now to turn back to the trailer. It has indeed changed a bit, but it is really details. My biggest hurdle will be figuring out the fabrication process so I get a smooth and strong roof structure without too much headache.
I want to use XPS foam due to high strength, but it off-gasses forever. This causes disbonds if you don't handle it. Surf board guys have vents for it, and so will I.
To get curves with a very rigid foam, I would either need to make slices and carve on it endlessly, or make kerf cuts in it.
Example of kerf cut:
I made a round peninsula end in my kitchen, using bending plywood. No need for kerf cuts there. I wainscoated it with bending oak on the circumference top and bottom, and applied a curly maple veneer. I had verticals to do on the wainscoating. I wanted a curve on that vertical like this.

It is subtle at 21.5" radius. The material is kiln dried hard maple and it really does not bend, so I kerf cut it like this:

I will test that process with 2" XPS. Single cuts along a simple radius will yield a semi-faceted radius. Not ideal but far less laborious than slicing and grinding away, but the side benefit is handling the off-gassing. If I control the resin during layup I will have channels throughout that I can drill a vent in.
This will work along the sides until I start following the compound
curves of the template. I will have to cross cut it as well, yielding a pattern of softened square elements, or diamonds if I get creative with the saw.
I may be able to soften those facets further using heat during the bending process.
I will build a male form out of wood and use stainless wire to tie it down, then glass and epoxy the outside. I will pull the wire in below the surface, and then cut it off below and leave it in the structure.
Flip it and glass the inside, and drill vents to the inside. In the gridded areas the cuts will form interconnected channels that will require few holes. The simple radius will require more.
The interior finish will be a glued on carpet or headliner that will not block the vents.

08-02-2015, 11:22 AM	#48 (permalink)
skyking Master EcoModder Join Date: Apr 2011 Location: Tacoma WA Posts: 1,399 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 Thanks: 743 Thanked 528 Times in 344 Posts	I mentioned some house remodel and truck mods to do first, what 3 years ago? I have a different truck that needs a cleanup, and I have touched every room in the house now. I am finishing up the kitchen in the next weeks so that will be done. Now to turn back to the trailer. It has indeed changed a bit, but it is really details. My biggest hurdle will be figuring out the fabrication process so I get a smooth and strong roof structure without too much headache. I want to use XPS foam due to high strength, but it off-gasses forever. This causes disbonds if you don't handle it. Surf board guys have vents for it, and so will I. To get curves with a very rigid foam, I would either need to make slices and carve on it endlessly, or make kerf cuts in it. Example of kerf cut: I made a round peninsula end in my kitchen, using bending plywood. No need for kerf cuts there. I wainscoated it with bending oak on the circumference top and bottom, and applied a curly maple veneer. I had verticals to do on the wainscoating. I wanted a curve on that vertical like this. It is subtle at 21.5" radius. The material is kiln dried hard maple and it really does not bend, so I kerf cut it like this: I will test that process with 2" XPS. Single cuts along a simple radius will yield a semi-faceted radius. Not ideal but far less laborious than slicing and grinding away, but the side benefit is handling the off-gassing. If I control the resin during layup I will have channels throughout that I can drill a vent in. This will work along the sides until I start following the compound curves of the template. I will have to cross cut it as well, yielding a pattern of softened square elements, or diamonds if I get creative with the saw. I may be able to soften those facets further using heat during the bending process. I will build a male form out of wood and use stainless wire to tie it down, then glass and epoxy the outside. I will pull the wire in below the surface, and then cut it off below and leave it in the structure. Flip it and glass the inside, and drill vents to the inside. In the gridded areas the cuts will form interconnected channels that will require few holes. The simple radius will require more. The interior finish will be a glued on carpet or headliner that will not block the vents. __________________ 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 Last edited by skyking; 08-02-2015 at 11:27 AM..