More wall construction and the floor

Once all sections of the wall were complete the skins were trimmed back to the size of the original frames with a trim router. 

..and fitted back into the metal framework.

The external ply was left uncut with the exception of the rear window and door. These cutouts will be made once fully ready to fit the windows. The wooden frames provide a guide for the trim router and the internal wall panels were trimmed back to the frames. 

Floor construction method was similar but this had to be built in situ. Underside of the lower floor panels was varnised before fitting. 

It is worth noting for historical context that at this stage of the project the coronavirus outbreak was starting to take hold. We decided to move ourselves and the project bac to the UK since it was uncertain how long this problem would last. 

There are not many photos of the next few days of work. Time was a bit pressing.

The roof was installed. 6mm marine ply screwed directly to the metal frame and sealed all round with Sikaflex. Wall panels were sealed and screwed in place. 

We then loaded it up. 

... and set out for home.

Wall panel construction

A bit of a catch up.........

We moved the project to a warmer and drier part of the world to continue the work.

The frame was deomounted and painted with hammerite.

The side walls are to be comprised of 3 panel sections, laminated with a 40mm PIR insulation core, internal wall of 4mm ply, external wall of 6 mm marine ply. 

Methodology.

Construct a light wooden frame within the metal frame. 

Use this frame to size and mark the insulation material. 

Cut the insulation to size and fit inside the wooden framework. Glue with expanding foam glue. 

Once the glue has cured mark and cutout frames for windows and hatches 

Glue the frames in position

This creates the 3 wall sections which can now be removed to apply the internal and external skins. 

Glue is applied. The skin ply place in position and the section placed in the improvised press while the glue cures. 

Turn over and apply the other skin using the same methodology. Shallow holes were made in the insluation board to provide a key for the expanding foam glue.

Wheels

The plan now is to move the frame to a place where I can work on it indoors for a while to get things weather proof. To this end I need wheels. 

I found heavy duty wheels with a 20mm axle hole. Brackets for these were fabricated using a 20mmm mild steel rod.

An R clip will hold the wheel onto the axle. 

On board

With the frame on board it was off to the supplier for the timber for the walls floor and roof. 

Demounting system

I looked at various ways of supporting the camper to move it onto and off of the trck bed. There are some very sexy and expensive ways of doing this around. I happened a kit of four legs and a jack for about 200 pounds from Edwards Trailers. 

The legs have two hooks at the base to carry the weight and a lug at the top for stability. I created suitable brackets for these. 

These brackets are removeable. It is worth pointing out that I envisage that removing the camper will be a seasonal and not a daily event; I don't envisage removing it 'on-tour'. Part of the plan, of course, is for the vehicle and camper to be transportable in a shipping container. This plan envisages de-mounting the camper onto wheels, hitching the truck and camper together and driving both into the container. 

With the stands all attached the scaffolding was dismantled and the truck (gingerly) reversed beneath it. 

Completing the frame

The frame was moved from the back of the truck onto the scaffolding base for completion off a level base. 

Central floor support added and underside painted

Frame turned over and first corner post being positioned

Positioning the roof support frame work onto the corner posts. Small sections of steel were welded at the underside of the roof frame at each corner. These dropped into the top of the corner posts and simplified the positioning job (by one man).

Roof frame in position 

Laminate Floor

Laminated Floor strength test.

Following a bit of research into floor construction I decided to experiment with the creation of a laminate floor panel based on ply/expanded foam/ply laters. 

Adhesive used was Screwfix no-nonsense expanding (solvent free) sticky foam. Mid later 30mm XPS styrofoam. These layers were glued, pressed together under weights and allowed to dry overnight.

Top surface 12mm of softwood plywood. 30mm XPS styrofoam, bottom surface 4mm plywood

Output is light, strong and inflexible. The beams here are at 750mm centres and there is no flexing under my weight.