SikaFlex Bonding Composite Panels - How to build an Overlander
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- เผยแพร่เมื่อ 20 เม.ย. 2016
- I can't recommend any panel manufacturer who deals with consumers in small quantities like this, The company I got ours from has asked me to stop referring people to them for projects like this. In the beginning, I really wanted to find a source for foam injected honeycomb. One such maker is RhinoKore, but they would not return my calls.
Join us as we bond our composite panels to the aluminum exoskeleton using SikaFlex 252. This video shows just the floor and ceiling installed, but they were the most difficult to get installed due to the size and weight. I'm hopeful that the smaller pieces can be trimmed in the table saw much faster.
![The Great Adhesive and Sealant Strength Test - (Lifeboat Conversion Ep5: Adhesive Test) [4K]](http://i.ytimg.com/vi/Uf4GhpBcaNU/mqdefault.jpg)
I am really impressed. Love seeing the whole vision come together.
The build and process is top notch. I wish I’d stop making excuses and start making progress. For now I have a Jayco popup cab over, truly a piece of crap but gets me out of the weather and warm. Thank you for taking the time to do what you do for us.
Nice job I'm going to go back and watch them all!
Your wife cracks me up (in a good way; love her energy). Am really enjoying your videos; thanks for sharing them with us. You're really doing a great job on this build.
Wow, that's some impressive work!
Thanks so much for posting the videos ladies.
Our pleasure!
Those composite panels seem to handle ok for what you are doing. On a side note, while in GTO going to university a neighbor built a one seater jet in his apartment and I wondered how he would get it out? He just took it apart and reassembled it outside. Keep up the good work and video too....
mad respect.
Nicely done!
Any pro/cons feedback about your honeycomb solution vs ... About insulation? soundproof? lifespan? technical choice?
If you had to start the project today, have you spoted a new material that you would try on?
thx
Fantastic build , where did you have the doors made and how thick are they and what price did you pay. You are a inspiration to me building a expedition vehicle.
Hello from BC!
I have been following you guys for a while and have had a question since day one, figure it’s time to ask!
Why did you design your camper with all the odd angles?
Do you not lose out on interior space and add a bunch of extra work doing that?
Thanks and keep having fun on the road!
Hey love your build! Thanks for all the ideas. I have some raw honeycomb panels I'm bonding aluminum skin to. Any recommendation for the adhesive?
No, sorry.
Thanks for the content. I'm not familiar with the properties of the panels which you worked with however there are many products which do not require framing due to their internal strength.
Correct, These do not require frames either...
@@Everlanders Thanks for clarifying. Cheers from Oz
so cool. Really nice work. Love the alum design. Cannot go wrong with alum, slightly more expensive but so light and lasts a lifetime with no rust to worry about. Curious, where did you get your panels and how much did they cost?
everlanders.com/faq-honeycomb-composite-panel-supplier/
Awesome! I'm considering building. I'm thinking about just a 10 or maybe 12 foot van body with spray foam. Does the composite builds come out much less weight or offer many other advantage?
It is my belief that composit boxes are much lighter... Our complete box, fully loaded with furniture and everything is 1200kg... th-cam.com/video/lpzkHvQA-t8/w-d-xo.html
could you share where the doors were made?...awesome job, thanks for documenting it!
Great videos! You briefly mentioned it but is there a reason why you went with the honeycomb style panel and not a foam core or other type of panel. What level of insulation do you have with this combination?
My testing of foam cored, fiberglass skinned and aluminum skinned showed they suffered from easy delamination when a bracket was riveted or any twist applied. Further, the solvents in the paints and spray adhesive I used melted the foam on the edges of the panel. Get a sample and test carefully if you choose a foam core panel. I would recommend RhinoKore foam impregnated honeycomb, but I think they went belly up.
When I first saw honeycomb I was like,that has little insulation value, but I see it has foam inside, never heard of this material before, so definitely want to know more about its insulating value, i'm sure its plenty strong, but I'd think polyiso foam at higher density is plenty strong too, or even the real pricey boat hull foam, although you don't need all that much for a camper vs a 50ft boat.
@@Everlanders do you have a part number or link to the panels that you used?
everlanders.com/faq-honeycomb-composite-panel-supplier/
Have there been any issues with the thermal expansion differences between the aluminum frame and composite panels?
Nope, That's is why the SikaFlex 252 was used and has an eighth inch spacer gasket before it cured.
helluva job! I wish I had a partner like that. is she really as enthusiastic and supporting as it looks?
+Waynes Grid Yes indeed! But to be fair, it was her idea and drive to make it happen in the first place.
Wow! I can't find one of those. My wives have never been supportive or interested in helping. Makes it hard to finish when you know she doesn't like your projects
How's your conversion coming?? I've been waiting to see your next video/interior layout...
It's coming thanks. Actually, I'm replacing the front seat right now with bucket seats so I can cut a pass thru from cab to box. post up tomorrow maybe, what do you use for editing videos?
DaVinci Resolve 12.5 - a tough bronco to tame...
hey im in BC. i understand your in canada too what is a rough figure on matierials (aluminum and paneling)
Let's just say you could purchase a similarly sized, nicely outfitted camper trailer for the same price or less. You really have to want to go this route for reasons of durability or customized layout and function. If you just need a cheap camper on an old truck, this isn't the way.
What is the brand of composite panels that were used?
That awsome wondering wher you purchase your composit sheets
It's kind of irrelevant where I bought mine, I assume you don't want to export these from Canada... If you are in the United States I would recommend www.boxmanufaktur.com
How are the joints between the panels holding up in terms of water ingress? Obviously there is a lot of movement underway, are you having any water leak problems between the Aluminum frame, sika, and fiberglass panel?
Zero Leaks, I'm happy to report (-:
Everlanders that is great! Do you recall which Sikkaflex adhesive / sealer you used?
Yes, Sikaflex 252 and the 206 (now 207) primer... If you haven't seen the solar video yet, it gives you a good idea how well it sticks, took me hours to cut through. th-cam.com/video/3nKCH-whO2A/w-d-xo.html
Awesome build will you guys be at Overland Expo 2020 In Flagstaff
We were at Expo 2019 in the Showcase Area, it's pretty unlikely we'll do 2020, we'll be Overlanding Guatemala by that time...
Our time at the 2019 Overland Expo: th-cam.com/video/RzjSWZw4MPg/w-d-xo.html
What's R value of these panels you are using and where can I read more about them.. You are doing some really amazing work.
everlanders.com/faq-honeycomb-composite-panel-supplier/
@@Everlanders interesting read. Thank you
Where did you get the panels?
I'm trying to locate information on how much weight a panel like these (not sure of the brand or tech used in my trailer, but I imagine the relevant part is the aluminum skin which are probably all the same 0.5mm or similar thikness) can support. I'd like to rivnut or cross-nut (plus-nut ?) some components in neighborhood of 20 lb to the wall, footprint approx 12"x18". The load would be mostly in shear but the thickness of the items (up to 8") would likely induce separation forces and not simply shear. I would only be penetrating the inner or outer skin and the core material with rivnut or cross-nut deforming that core material as it compresses and retracts. A through bolt is not desired for watertightness (and no way to get an effective bushing between the skins).
I've considered bonding or riveting a thicker sheet (16ga probably adequate) to buttress the skin surface to combat the tendency to *wobble* under load. But maybe this is overkill if the footprint is large enough to spread the load as it is.
Do you have any thoughts on this after working with the material? Or specific resources you could point me to? I'd appreciate any help.
I chose not to use aluminum skinned panels because in my testing with rivets and rivnuts they all delimitated too easily. Perhaps contacting the manufacturer of your trailer would be your best bet.
@@Everlanders
I have word in to them as well. Thanks anyway.
Thanks.
What panels did u use? because I called plascore and they said that they don't recommend it for that use ...
Correct, We did not use Plascore panels.
@@Everlanders so would u mind sharing what company u went with haha
I too am curious how you had the doors made. You can give a general idea if you don’t want to name the company. Thanks.
I had them custom made in Canada... If you're in the states, you can just order it on Amazon...
That was easy! Thank you. Thanks for the videos too. The battery and solar panel video was very helpful.
this is many year away in your memory but if you had to guess...how many tube of sikaflex 252 did you need for this? and how many bottle of 250ml primer?
12 or 15 tubes and probably 750ml of primer.
Hey Jason, I am bonding my aluminum solar panel brackets to my fiberglass camper roof using 252. Did Sika 206 become 207? Also where did you buy your Sika supplies from? Seems difficult to find the primer in Canuckistan.
Yes, 206 is now 207... I bought most of ours from Rondex.ca out of Winnipeg, but I was able to get some small tins for odds and ends jobs at a local Windshield Glass Wholesaler called Vanfax in Saskatoon.
@@Everlanders thank you! We have a Vanfax near us in Cranbrook. Will try them.
@@Robbbbooo The best applicator I found was made from a chunk of thick felt, tied with wire to a stick... Bristle brushes drip and run, and foam just melts...
@@Everlanders perfect. Will try that. By a stroke of luck my local body shop had a few tins of 207 they were willing to sell me. One step closer to Baja!
How durable has this stuff proven to be? I am in the middle of a similar project but looking at coolroom panels instead.
Ours is still going hard with no problems... If you choose a foam core be sure to test. I could not find one that I felt was acceptable, they all failed my delamination testing and melted when I had solvents in the same room.
@@Everlanders Your talking about the polystyrene with the metal laminate panels that lock together?....The stuff you used is available here in Australia but it is 5 times the price so I can't really justify it.
Correct...
@@jedics1 Yep.. everything is 5 times the price here... beyond a joke. So much for globalization.. we have no industry, no machinery, no skilled people .. so we are at the mercy of the exchange rate
What did you use to secure your build to frame of truck
th-cam.com/video/7_NlZw3lk3A/w-d-xo.html Box mounting starts at 10:45
It’s kind of amazing and annoying that it’s almost impossible to find a source of composite panels in the USA. Seems like a no brainer, just think of the prefab/modular projects, cabins, disaster housing, campers, even housing. Skins could be aluminum, abs, wood, fiberglass. I’ve searched and they just aren’t available to the consumer. Please correct me if I’ve missed a supplier.
There are many.
Hi guys, are the panels fused or bonded? ( sorry if you’ve covered this elsewhere )
We used SikaFlex 252 with 206 primer.
I wish I could see the closeup of the rivets. I don't really understand how you got the ceiling up so it could bond without gravity..
You've just explained it perfectly, the rivets hold the ceiling up so the Sikaflex can bond properly. After the bond has cured, they are no longer needed, but we kept them for style points.
And for a close up of the rivet, just google Tri-Fold Rivets or Butterfly Rivets.
Maybe I've missed it, where did you get the panels from?
everlanders.com/faq-honeycomb-composite-panel-supplier/
you mentioned the primer which adhesive did you use
Sikaflex 252 and 206/207
which mastic did you use after sika 206 primer?
SikaFlex 252
Will it fit out your garage door?
Like this? th-cam.com/video/2MlN0xplkJQ/w-d-xo.html
I have the same harbor freight creeper
We don't have Harbour Freight in Canada, but they probably all get them from the same overseas provider!
What primer are you using with the Sikaflex-252?
206 and 207
What kind of Sandwich panels do you use for this body ？
Fiberglass Honeycomb Composite Panels
Everlanders can you give me a e-mail address ，some question to inquiry ，thanks
Did you document the SolidWorks
No, Sorry
Where do you get these panels please
everlanders.com/faq-honeycomb-composite-panel-supplier/
Should have fiberglassed it all together sealed the seams inside and out stronger luther and no need for framing absolutely no leaks or draft better thermal
And then just fiberglass it to the frame? I went and checked the videos on your channel but found no clear instructions...🤔
What brand are the composite panels?
I can't recommend any panel manufacturer who deals with consumers in small quantities like this, The company I got ours from has asked me to stop referring people to them for projects like this. In the beginning, I really wanted to find a source for foam injected honeycomb. One such maker is RhinoKore, but they would not return my calls.
👍👍ls it an aluminum frame?👍👍🇰🇷
Yes, shown here: th-cam.com/video/Dt3T_DRVno4/w-d-xo.html
anyone heard the thickness??
I did.
@@Everlanders not easy to catch some phrases for non-native followers bro.
great series tho, watching all for hours.
By the way you can angle a jig saw too!!! ( just saying ).
No blade I found was long enough for the diagonal.
@@Everlanders , oh.
As a composite repair man for 20+ yrs, I can tell you that beard of yours won't suffice as a respirator. Those fine dust particles of glass fiber will get in your lungs and never come out.
PS, did you treat/protect the edges of the plywood?
No, the plywood in that panel was marine grade, and it's sealed in there pretty good with the Sikaflex already...