Building a platform for the bed - Hexcel?

[AndrewST]

Originally Posted by spomo1

Do you have any deflection numbers for these on a 40" span? Its possible that no frame is needed..

I didn't get that far and am planning doing the bed board with it, as you.

The only one that has stock and could deliver one or two boards is paneltec and they can give the deflection of the product.

Unfortunately they didn't reply to my request yet, will try again...

[axel]

Since they use nomex foam and aluminum sandwich for the floors of helicopters and commercial jets as well as load bearing panels for other structures, such as boats and cars I think your idea is an excellent one. You can make the panels yourself with balsa, foam or hexcell core and thin ply or fiberglass faces. There are load tables available and you can calculate what the dimensions and materials you need for the load and span. Very much lighter than solid ply or aluminum framing.

As a very rough guide, and obviously dependent on material choices (what core material, what density of core material, what facing etc) you will get the same rigidity from a 1/2 inch composite board as you would from an equivalent thickness of solid material like ply.

Boat building suppliers like Noah's Marine or aeroplane suppliers like Aircraft Spruce will have the materials as well as load info.

[Sandi]

Originally Posted by axel

Boat building suppliers like Noah's Marine or aeroplane suppliers like Aircraft Spruce will have the materials as well as load info.

Neither site had the pre-made panels - they had the raw honeycomb cell stuff, but not finished panels.

Bummer.

Sandi

[axel]

Sandi, try this for finished panels and poke around the net a bit, you'll find all you need.

http://nida-core.com/english/nidaprod_l ... posite.htm

Typically foam or hexcell are lighter than balsa and for a bed you won't need the additional shear and crush strength of balsa.

[axel]

Also look at this page for some idea of how stiff this stuff can be:

http://nida-core.com/english/nidaprod_l ... p_h8pp.htm

[Sandi]

Thanks, Axel, I'll check it out.

While noodling on another site, I came across this one for a custom Sprinter van conversion-

http://www.outsidevan.com/espar-pony.html#

You have to scroll through the picture gallery, but pay attention to the rear couch with the panels above.

They've used the Hexcel panels in their bed setup. However, instead of a removable aluminum frame, they bolted channels to the walls of the van, and kept the panels as separate pieces. This is even more adaptable than a removable welded frame, I think, and probably less work to make. Yay!

Sandi

[BroncoHauler]

Originally Posted by Sandi

Thanks, Axel, I'll check it out.

While noodling on another site, I came across this one for a custom Sprinter van conversion-

http://www.outsidevan.com/espar-pony.html#

You have to scroll through the picture gallery, but pay attention to the rear couch with the panels above.

They've used the Hexcel panels in their bed setup. However, instead of a removable aluminum frame, they bolted channels to the walls of the van, and kept the panels as separate pieces. This is even more adaptable than a removable welded frame, I think, and probably less work to make. Yay!

Sandi

I like the interior, but man, get some windows in there. It looks like cubicle-hell for Dilbert.

[Christopher Thwaites]

Sandi,
Go to my gallery pages 2 and 3. I made a frame out of 1" square tube and then the platform out of cabinet grade 3/8 plywood cut into 2 sections. It is easy to remove, light weight and cheap! We sleep across the van. It's 6" and we are under that. I put the mattress at window height to gain the full width and max storage underneath.
Chris

[Sandi]

Originally Posted by Christopher Thwaites

Sandi,
Go to my gallery pages 2 and 3. I made a frame out of 1" square tube and then the platform out of cabinet grade 3/8 plywood cut into 2 sections. It is easy to remove, light weight and cheap! We sleep across the van. It's 6" and we are under that. I put the mattress at window height to gain the full width and max storage underneath.
Chris

We can't do that. DH is over 6', so it has to run front to back.

And we've both had spinal surgery, so I suspect your definition of lightweight (40 lbs each section?) does not equal ours.

But thanks.

Sandi

[Christopher Thwaites]

We weigh 300# combined!