Building Materials

[Zaskoda]

So, the girlfriend and I have started the conversation about building our own camper van (as I mentioned in another post). I've been reading up on many of the posts here and elsewhere about dyi builds.

I keep noticing much of the construction being done with plywood. While durable, this seems like a heavy material to build with. Are there other materials folks typically use to keep weight down? It seems that plastic combined with metal framing might be a viable and lighter alternative for some components - but I haven't seen that type of construction in any of the builds I've looked at.

I keep thinking back to the way boats are designed. It seems to me that the building methodologies for RVs in general are way behind the methodologies used in boats... but maybe I'm comparing apples and oranges?

Insight?

[charlie56]

I would have loved to use lighter weight materials, but cost was a big factor in the decision. Its hard to beat the low cost of plywood or MDF. Try googling composite panels or honeycomb panels. They are used in the aircraft industry but they will also come with a hefty price tag. A sheet of 3/4" A/C plywood is going to weigh around 70 lbs and cost $40 - $50. A 4x8x3/4" composite weighs 25-30 lbs and costs around $275. The you need to laminate a face on it.

Check out http://panelteccorp.reachlocal.com and navigate to their stock panels.

[billwilson]

my cabinets are being build out of ultralight wood
pre skined
half the weight of mdf

will get specs from my builder

my entire passenger side frame w/ drawers
and cabinet weighed less than 1/2 the one removed

check out my pics the week of the 12th

[LenS]

The walls on ours are 6mm (aka: 1/4" birch veneer plywood) and are very light. The storage boxed on either side of the 20" center isle are framed in 1"x3" poplar that is glued to same 6mm plywood. The tops of the boxes are 1/2" plywood, and the 6 drwr cabinit is the heaviest construction made out of 1/2" & 3/4" birch veneer plywood. Room dividers are 3/4" birch veneer plywood. I really do not consider that over kill and in a 3/4 ton van it is not much weight.

IF, IF, IF we get in a fender bender I want everything that is stored to stay were it is. I feel comfortable with the construction and the weight required to make it.

[Zaskoda]

Originally Posted by LenS

IF, IF, IF we get in a fender bender I want everything that is stored to stay were it is. I feel comfortable with the construction and the weight required to make it.

Now that's something I never thought about. I was once involved in a collision with scuba bottles in my truck. It was relatively low speed but the way they moved made me realize how risky it was to drive around without them secured in any way.

Thanks to everyone for their input. =)

[jage]

No matter how thick the cabinets, the latches are only so strong.

My SMB pressboard (laminate?) got a little wet recently and now there is a nice big bubble at the bottom of one of my cabinets. Not pretty, not fixable. Something to consider when choosing materials.

[Zaskoda]

I looked at a lot of cool things built with plastic at the container store. Seems like one could do a lot with plastics.

[billwilson]

Check out the pics in my gallery
My cabinets weigh 1/2 of stock and are real wood

A "no frills" interior made from real wood, of the Ultralight variety
would be very cost effective, even if done by pro vs self install

JMHO

[Zaskoda]

I found this to be very inspiring:

http://www.livinlite.com/construction.php

[TroySmith80]

Originally Posted by billwilson

Check out the pics in my gallery
My cabinets weigh 1/2 of stock and are real wood

A "no frills" interior made from real wood, of the Ultralight variety
would be very cost effective, even if done by pro vs self install

JMHO

Old post but that's ok...

Bill, is Ultralight the brand name? Where is it available?