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  #1  
Old 25 Dec 2007
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Camper Body Wall Construction Material
I'm looking to cost the conversion of a 4x4 lorry; there are a number of differing methods to construct the body.

One option that has come to light is a glass fibre reinforced laminated board instead of steel/Ali sheeting. Problem is I don't know the name of the board or any suppliers, can anyone help?

I believe its similar to ply wood except stronger and has a durable hard surface on the outside.
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  #2  
Old 25 Dec 2007
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Hi Josh,

You are thinking of Composites, available in a variety of forms, weights, etc.

I share a workshop with someone that converts lorries into Horseboxes and he has used it a few times. We have been looking into using it for storage solutions in expedition trucks, however it is expensive.

The best place to look for suppliers is in the commercial trucking world.

Are you going to be doing the conversion yourself?
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  #3  
Old 26 Dec 2007
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Sounds like the same stuff they use to make refrigerated lorry bodies out of and is much better than metal on wood for an overland truck body IMO. You can buy nice overland-ready shells in Germany (all glued, no metal frame) for around 10,000 euro (see pics) or you can track down an old refridge body as we thought about (on Merc 800D?? vans I believe). It will come with kick-ass air-con too!

Ch
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  #4  
Old 26 Dec 2007
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Info
Have a browse through this web site, a conversion of a Unimog. He has lots of info about stuff.
The UK Unimog owner's meeting place.
And click on "converted into a campervan"
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  #5  
Old 29 Dec 2007
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I've heard good things about the Nida-Core composites.

Nida-Core Lightweight Composite Honeycomb Core Materials and Structures

Nick.
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  #6  
Old 1 Jan 2008
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Hi Josh,
the europeans have got this of to a fine art - and they are great,
Ali sheet works well until it starts to separate from the frame - which happens - albeit after quite a few years.......
'plastic' is the way to go
what truck are you using ?

this is a rather nice Steyr S21 4x4 we travelled with in Mauri - not sure who made the box - but i remember the owner saying it was 10-15000 euros ish unfurnished - well insulated and hermetically sealed - no sand ingress at all on the pistes - which is doing better than the 90 !!!

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  #7  
Old 1 Jan 2008
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Happy New year to one and all.

Quote:
Originally Posted by Gipper View Post
Ali sheet works well until it starts to separate from the frame - which happens - albeit after quite a few years.......
The key with joins between Aluminium and Steel is that you have to put a seperating layer between the two, otherwise the Aluminium will eventually corrode.

We usually use double sided tape or bonding mastik to keep the different metals apart and this prevents the problems.
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  #8  
Old 1 Jan 2008
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Thanks guys
Thanks for you comments, I've been looking at some of the European bodies from the likes of Unicat and Langer and Bock. I want to use the same material to build my own body for the rear of a Leyland DAF 45 4x4 or a Unimog U100L.

I was looking for a material name or something so I could speak to some of the local Truck Coachbulders to buying the right mateial.

All info greatly recived.
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  #9  
Old 1 Jan 2008
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AFAIK you can't buy it by the metre or in panels; the GRP sandwich examples in my reply above were cut to size and bonded together to the thickness required under a high pressure press using special glues. And then you glue the pre-formed panels together to make a box (which door/window holes as and where).
I got the impression listening to the German bloke selling the shells (made in Spain, actually) that to DIY to anywhere near their very high standard would be tricky, but that is all you have to do or get done.

good luck

Ch
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  #10  
Old 1 Jan 2008
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try this company
Service Metals Commercial Vehicle Fittings Catalogue

Look under grp panels.

Graeme
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  #11  
Old 2 Jan 2008
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Quote:
Originally Posted by Chris Scott View Post
AFAIK you can't buy it by the metre or in panels;
Yes you can ;-)

Yes you can get pre-assembled panels or you can get sheets as you do with ply and then cut them to your own requirements.
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  #12  
Old 3 Jan 2008
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this is a german company but they sell the panels cut to size in various thicknesses with all the appropriate fittings and hardware:

ORMOCAR Reisemobil GmbH: Sandwichplatten, Wandplatten, Deckenplatten, Bodenplatten, GFK

not sure how the price compares to getting them to make the whole box for you.

Hope this helps,

regards,

nick
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  #13  
Old 3 Jan 2008
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You can get panels and various profiles to fit it all together in Germany through AMR-Outdoorwelt Trekking Allrad Offroad Expeditionen Fähren Camping Reisen Abenteuer. Click "ausbau und wohnen" and then "wohnkabinen".

Probably not practical to have panels shipped to the UK, but of interest to see a DIY option, with special panels for floor, and even panels with pipes prefitted inside.

Pieter
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  #14  
Old 29 Jan 2008
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RTM Styrofoam
As others have mentioned, you can use the sandwich panels manufactured for the frozen goods delivery vans - there are several UK suppliers. RTM Styrofoam is the modern version and what I went for in my daily 4x4 conversion - very light, very rigid and very insulated. Also easy to cut and glue together.

cj
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  #15  
Old 9 Jul 2008
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Try and contact this guy in holland Contact . He has some kind of composite and he claims that it is so hard that if you hit it with a hammer it doesn't even dent. He uses epoxy glue to get it on the metal frame.

regards

Henk Jan
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