How to Build RV Fiberglass Filon Plywood Foam Composite Sandwich Wall
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- čas přidán 21. 08. 2024
- This video demonstrates one technique used to fabricate a composite wall panel like ones used in Recreational Vehicles and Motorhomes.
Composet Products L.L.C. high performance laminating epoxy is used for the best strength and water resistance. The Composet adhesives are Styrofoam safe and are easy to use. The panels include Filon fiberglass FRP skin adhered to plywood or luann, wood and aluminum framing, Styrofoam, and paneling.
Do-It-Yourselfers can easily build these panels to made home built campers and custom camper vans.
One question that regularly comes up on RV forums and chat rooms is how to rebuild water damaged RV walls using new materials and specifically how to bond Filon to plywood. We found no easy answer, so we looked into the situation. Here's what we found.
In the past many RV manufactures built the walls in a factory by gluing layers of fiberglass, wood, and Styrofoam together with contact cement. The main advantage of contact cement was the immediate bond that occurred when the parts were joined together. Contact cement worked well, however flammability and toxicity issues pushed manufacturers to find an alternative that was easier to handle and store.
Currently a number of manufacturers are using hot melt glue, which is a high performance version of the "hot glue" you might use for crafts. This product has proven to be durable as well. It is easy to store, relatively non-toxic, and gains strength very quickly. However, the process requires a large, heated vessel to hold the melted glue, and an elaborate system of rollers to apply the adhesive. There is also a limited working time because the glue skins over as it cools.
We focus on DIY and one of the caveats of our testing included the availability of potential adhesives, as well any required special processing equipmen. We contacted a supplier of a contact cement that was the industry standard for years, however they we were unwilling to provide a sample. They did send us to a distributor, and the cost of a 5-gallon pail was around $1000. The product is pricey due to the high flammability rating and toxicity, (not legal to use in certain parts of the country), and must be shipped by truck freight. We deemed this product impractical to the average DIY'er, so we did not test it. However, we did select 3 off-the-shelf contact cements to test.
We also eliminated hot melt adhesive even though we feel a good DIY'er could build a backyard system. We contacted Henkel, a primary supplier, but were unable to get a sample for testing. Part of the problem is the holt melt being packaged in large bulk blocks. We were not even offered a chance to get it even if we were willing to pay for it.
That leaves us only a couple of options that we feel a DIY'er could find with reasonable effort and cost.
1. Off-the-shelf contact cement.
One-Part Construction Adhesives, and Marine Adhesive Sealants
Two-part epoxy
We purchased Filon and the adhesives from an online supplier as well as the local big box home improvement stores. We did a few initial trials to determine product compatibility and general bond characteristics. We culled the products and settled on final contenders. We fabricated 8" x 8" test panels consisting of a Filon/plywood/Styrofoam/plywood sandwich.
The materials were cleaned and prepped. We also used a heavy-duty roller (www.rvroofandwall.com) to assist in getting a good bond. Then we placed the samples in a homemade press where they cured for 24 hours at 70 degrees F.
We ran the parts through a heating and cooling cycle, and then tested at temperatures starting at 200 degrees F. An RV wall with dark decals or dark paint can reach temperatures as high as 160 degrees F in the summer.
Please note that we are not a scientific test lab. Our tests were developed by seat-of-the-pants methods and are not to be confused with a technical analytical study. The information we are sharing represents our opinion and observations.
Summary:
Building RV style walls in not an easy task, but well within the reach of skilled DIY'ers who have the space, tools, and ambition to tackle the project. The 2-part epoxies form Composet Products L.L.C. were the overall favorites, followed by the Loctite PL Marine. There are a few specific tools needed (roller, notched trowel, adhesive roller, press/clamp).
Very labor intensive cant imagine a full wall $$
Excellent post, thank you for sharing.
Very interesting and informative tutorial, thank you for sharing your knowledge.
Thank You
Very informative. Questions please: 1) Thickness of plywood? (I assume at least outer plywood is marine grade). 2) Total thickness of end product? 3) I an outer plywood really needed? Can we use thicker Filon (I do not know details of this product, other than it is fibreglass. Thanks, again.
In an rv there's no marine grade chemicals in it are poison to breathe. There's no set wall thickness but usually interior is 1/8 or 1/4 aluminum tubing walls are 1 or 1.25 (2x2 wood is 1.5)and exterior panel is 1/4. Wall panels are normally between 1.5 and 2 inches....oh filons just one thickness that I know of
@@brentsharp8234 Appreciated
@GoAndStay you trying to build a camper is that your reason for asking specifics?
@@brentsharp8234 thinking about it, but will probably not take it on. But most definitely looking and dreaming and planning! That is why I enjoyed this so much.
@GoAndStay if you enjoy building its fun to do I built my tiny camper last year it took about a month. You can get filon from recpro and use contact cement to glue it it's really not hard just time consuming
Why don’t you use a vacuum bag?
Bill, thanks for the comment. Yes, a vacuum bag is a better alternative to the method we used, however the home DIY'er may not have the ability for the VARTM process. And many in our audience are working on RV's and need to build a patch panel that can be done in place on the RV. Typically, RV wall structures are very porous, and it would be difficult to bag the wall or RV. Therefore, we demonstrated the clamp or press method. Thanks for pointing this out. We may produce a video using VARTM as we have the equipment in our shop.
Tedious !
Yep!
What is the specs for the Resin you used for the Filon adhesion to the plywood
Composet Compobond epoxy find it at www.delamrepair.com
What prep solvent do you use?
Automotive pre-paint Wax and Grase Remover
Not very high quality results, when you only compress it with external weight you create spots which are compressed more than other areas creating uneven flatness. You clearly see that on the edges. Vacuum bagging is the answer, not very expensive either, pump 100$ and bag material is filthy cheap. If you spend money to materials don't waste it with bad processes.
I agree with the comment as applied to a manufacturing environment. Typically, the manufactured RV wall installed on an RV, with many feet of lineal penetrations is way to porous and cumbersome to vacuum bag.
Overkill