Foam Bones Van Build System Vol. 1

Volume 1 of the Complete "Foam Bones" Camper Van Building System. Covering the build system overview, 7 benefits of building with Foam vs. Wood, comparing weight, cost and insulation value. Self built Ford Transit for full time #digitalnomad with foam core structure for ultra light and highly insulated van build.
CHAPTERS
=========
Pre-Intro 00:00
Introduction 01:24
Not my Idea 02:51
Foam Bones Concept 03:51
Materials 04:32
Cutting Tools 04:52
Foam Joinery 05:56
Strengthening Foam 07:52
Flexibility Advantage 09:14
Weight Advantage 10:16
Cost Advantage 13:12
Insulation Advantage 18:22
Labor Disadvantage 20:16
Where Not to Use Foam 22:35
Scale Drawings & Model 26:06
Why Mock-up 28:47
How To Mock-up 30:52
Why Not to Screen First 34:00
Bending Foam 37:24
Wood Veneer 38:44
Cutting Pieces in Place 39:34
Duplicating Similar Pieces 42:07
Secondary Structure 43:06
Completed Mock-up 45:05
Outro 46:01
{{{{{{{{ My Other Videos About Foam Bones Building System }}}}}}}}}}}}}}}
Prototype Foam Cabinet:
• Foam Cabinet Prototype...
Prototype Part 2: • Prototype Foam Cabinet...
Prototype Q&A: • Prototype Foam Cabinet...
Foam Weight Comparison: • Weight Comparison - XP...
Toxic & Flammable?: • Is XPS Foam Cabinets T...

[@INKonoclast]

My God, I can't believe KZbin has buried this. I've been searching for this sort of info for a long time. You present it so clearly and concisely. Time to binge watch everything you've got.

[@annag467]

I'm not crafty or handy at all, and i have no upper body strength. I have no garage. But all of these foam build tips have enabled me to insulate and make plenty of non-foam fixtures in my van. Thank you forever for these videos! My foam insulation keeps me warm for longer at night in the desert, and prevents me from burning my skin on the metal inside the van on a sunny day. Vital stuff!

[@falkornomad]

Awesome!!! Way to go!

[@tempeleng]

does the foam melt against the hot car body?

[@annag467]

@tempeleng no, the foam only melted when I tried to spray the wrong adhesives onto the foam. That's why foam needs a special foam adhesive, to avoid a meltdown. Certain adhesives and adhesive activators do this, I learned. And only hot wire heat can melt and carve the foam, otherwise, cheap eps foam is used to package and insulate heavy electronics for shipment all around the world for decades. Use foam!!

[@aaronfranklin324]

@@falkornomad big problem with your foams and synthetic resins and paints are they emit Extremely carcinogenic and hormone disrupting chemical vapours. You can remediate or eliminate this problem by casting or laminating natural fibres and low density foam like systems using Magnesium oxide/potassium dihydrogen phosphate chemically bonded ceramic rather than toxic synthetic organic materials. MgO / MgCl cements are more porous but less finicky and have longer working times. Are more porous and less water resistant. Sawdust, clay, pumice, cotton bedsheets, hemp fibre, whole chopped or long blackberry vines, bulrush reeds, split bamboo, glass fibres, pearlite or vermaculite or pumice pebble .... Are all compatible fillers and reinforcing. You can achieve non toxic, breathable, more insulating, more longlasting builds with costs less than one percent of what you are using with these systems that have been used for thousands of years. There are temples and megaliths all over the world made of "stone that floats on water", cast megalithic blocks indistinguishable from granite, basalt , marble.... These materials do not absorb infrared and solar light energy like polymers do, they do not trap condensation and do not emit chemicals that give you cancer and screw up your hormones, fertility and gut and mental processes. Ditch the toxic crap. It's been proven since the 1960s that molds and algaes and bacteria grow on these synthetic materials and break them down into toxic volatiles and microparticles. Why use this crap when you can achieve similar strength and weight to carbon epoxy foam composites with Natural free materials and binders that mix with water and set like stone or ceramic. Coating steel and other metals with the magnesium phosphate ceramics will permanently stop any corrosion. Coating timber will seal and stabilise it and eliminate decomposition and dimensional changes from heat or humidity changes. You can use it as glue to laminate timber to foam if you must, or mold mesh or natural fabric over your polystyrene foam if you must. Oil your timber surfaces with linseed oil and beeswax polishes.

[@falkornomad]

Everything I could find from independent websites about XPS foam does not support most of what you are saying. I have a video “… Toxic & Flammable” that covers some of this. Do you have a specific resource discussing XPS foam bing toxic you can share?

[@theresamcmanus2960]

I’m just watching your video for the first time. I cannot believe how marvelous, ingenious and absolutely amazing this is! At the age of 73, (and a husband who sadly has Alzheimer’s) I’m guessing I will probably never have the opportunity to use this information but oh how I am in AWE! Great, GREAT, G R E A T information! Thank you so much for sharing your information and experience. Seriously, may God bless you!

[@falkornomad]

You’re welcome, glad you enjoyed it!

[@billstewart3980]

You were my inspiration several years ago! Great to see you back. Built out a older sprinter short box van, ZERO wood. Foam coated with epoxy for walls ceiling and surfaces that are foam with thin aluminum bonded on one or both sides, 1 inch square aluminum tubing for framing where needed. I traveled the US for a while and now my daughter has lived in the van herself for the past year or so. Great insulation, super lightweight, easy to repair, cheap, easy to cut, looks super cool. Thank you Nomad!

[@christopherbrown6697]

I'm planning on incorporating some 1x1 aluminum into my van as well. I'm cutting up an old aluminum truck cap as a material donor.

[@falkornomad]

What a great story to hear! Glad I could play any part in it! You’re very welcome, my pleasure!

[@annag467]

Saaame, thank you dude for sharing the foam build content! His video on building a foam cabinet inspired me to use the hot wire to make an insulation barrier that fits between the driver cab and the cargo space, and more easily insulate my van 🙌

[@robertphillips3755]

❤❤❤

[@calysagora3615]

Would love to see that interior! got it documented somewhere?

[@ginnys9937]

Wow an actual teacher, and a real science and engineering approach! Best video I've seen so far! Thanks for doing all this work and sharing with us!

[@falkornomad]

You’re welcome… to be clear I’m an amateur at all of this, but I give it my best effort.

[@FranzKrachtus]

I agree. You are great teacher and know how to keep your viewer’s attention

[@falkornomad]

Thanks!! It’s mostly my good looks… and the small woodland creatures living in my beard 😜

[@colinkelley6493]

You warned us. It was going to be long but there was not a wasted minute or word. Well organized, well written, well said, well edited, in the right order, to the point. Much appreciated! Anyone else. including me, would have taken twice as long, and not covered it as well. You explained your reasoning quite well and convinced and converted me to do it the way you do it. In fact, I will go so far as to say, before watching this, I was only thinking about doing something like a home made cargo trailer conversion (into a tiny house on wheels to live in). Now, after watching this, I have definitely decided to do it. Before I was dreading it. Now it is fun and exciting, affordable, worth the effort, and can be built out of pocket, over time. I will include doing the 3D model, and full size mock up, for the exact same reasons you gave, but also because it is fun -- really fun. I am ordering a portable drafting table today. Thank you!

[@falkornomad]

Love to hear this… if there is one thing I wish I could do for the community, it would be to encourage people to get out of the planning phase and into the doing phase! Best of luck to you!!!

[@PielotKrys]

Exactly! This comment here, anyone who skips through will miss out on valuable information.

[@itoibo4208]

@@falkornomad well done video. This would be fun to do glass over, making it one big unit with smooth, glossy, surfaces, easy to clean and very modern looking.

[@falkornomad]

👍🏽

[@matthewknight5641]

Man the time and effort you have put into this process and then the way you have made the videos to help your fellow builders ... it says so much about where your heart is. This is just amazing in all ways. Thanks man.

[@falkornomad]

👍🏽

[@lawrencedobesh776]

Have you ever considered Doing a build on a pontoon base to build a small house boat? I would love to see that I think it would be ideal!

[@ZefOrath]

Maybe I missed it skipping around, but there's also noise cancelling quality of the foam. And this for me is important as getting a good night rest at a noisy campsite or stealth camping in the city can be difficult.

[@falkornomad]

It’s not mentioned but it’s probably true… hard to compare the difference… although the windows are the most likely place for sound to come in or go out of a van.

[@feedbackloupe]

I've had success with 3M Super 77 and the durable plasticy packaging foam that comes with new products. Its not as dense as the commercially available rubber sheet stuff but it'll knock down vibration way better than nothing.

[@stevescuba1978]

A few years back, i made an entire camper trailer out of foam covered in canvas. It slept 3 + 2 dogs, was comfortable in temps from 0 to 75 degrees with only a fan and windows for AC. I built old sailboat style windows that allowed us to have them open even in a pouring rain. I hauled it all over the western United States, barely affecting fuel consumption (fully loaded camper weighed around 1000 lbs). A friend of mine followed my lead, and he built a 16x8 camper trailer skinned with canvas, interior walls covered in luan. His slept 5-6 had a full kitchen and bathroom, and heat/ac. Foam makes an excellent building material that has been proven to hold up. I put well over 10,000 miles on the camper, bashed a few limbs and endured numerous nasty storms. The camper still looked new when i disassembled it after 4 years of use. Btw, I used gorilla glue and expanding spray foam in the various areas to assemble the structure, using packaging tape as clamps. I used titebond waterproof wood glue to saturate the canvas skin, then painted with latex paint. The skin was incredibly tough and still flexible.

[@falkornomad]

I have a few future projects with foam exteriors that I plan to do this way… good to hear that it holds up to the occasional branch bashing!

[@stevescuba1978]

@@falkornomad I did have one pop a small hole in the canvas, but I just added a few drops of glue and smoothed it out... good as new. I backed straight into the branch in the dark, so not a light tap.

[@falkornomad]

👍🏽

[@daniellehoward4583]

Hi! I'd love to connect with you for tips pleeeassee. I don't have much experience, but I'll have to live in one of these or be homeless so I could use all the help and mentorship I can get 🦋

[@stevescuba1978]

@@daniellehoward4583 what would you like to know?

[@JoannePughessenceforabundance]

I live in Cannada and it gets really cold here in the winter. The extra R value in this build is beyond genius not to mention the light weight construction that would save thousands of dollars in fuel costs makes the extra little bittle of labor an essential step in the build process. I am beyond grateful that you have taken so much time to put these videos together to teach others how to do this. You are a Master at working with this material and I love the flexibility and versatility the foam provides even in creating the rounded corners for cabinets etc. I will definitely be sharing this video on some of my camp sites for others who use vans/RV'S/trucks etc.

[@falkornomad]

Thanks for the thoughtful and kind comments and for the shares! Cheers 🍻

[@bkruger377]

NOMAD has produced the most well organized, information rich, fact filled DIY video(s) I have ever seen. Within a couple minutes of watching I realized he is a unique talent and I became a subscriber. The amount of credible engineering data that NOMAD generates and incorporates in his presentation never gets dry or boring because he keeps the volume and the pace of information flowing at a constant but digestible rate. He is a real talent and a masterful content creator. If he were a University Professor his students would be sitting on the edges of their seats through his entire lecture. …..BRAVO. and THANK YOU.

[@samsteel2643]

Can cut dovetail easy with that hot knife, and really strengthen the joints. Love the thought of window screen and paint. So creative

[@garywheeler7039]

I assume the screen is vinyl as most is these days, and not aluminum. Anyone know for sure?

[@BigPubez69]

​@@garywheeler7039I've only ever seen it done with vinyl

[@ginnylaw]

@@garywheeler7039he puts up a screenshot at 13:45 id assume he used the same so it’s fibreglass

[@garywheeler7039]

@@ginnylaw : I see that now, thanks. Technically a strong fiberglass with vinyl coating I guess.

[@Seqhael]

If it were me, I would make up a jig to get absolutely perfect dovetails every time. Would be super easy to do, a template each side of the foam and drag the hot wire along the templates

[@KarlKarsnark]

These sorts of "SIPs" (Structurally Insulated Panels) have been around for a while and are used to make walk-in coolers, sheds, etc...Boats also use this sort of foam-core and fiberglass layup. Just takes some special tools and learning some new techniques from traditional carpentry.

[@falkornomad]

👍🏽

[@kittyblue8310]

I’ve been watching van build outs through RVliving ( Bob Wells) and I shake my head when I see how much wood they use in their build outs & laugh when they can’t afford the gas for traveling…. That being said, I think your idea is genius, and even if it takes more labor, I think it’s worth it …. I love how well thought out everything is …. I think the algorithm is working because your video showed up on my feed & i’m glad it did … Your ideas are definitely important in van build outs….

[@falkornomad]

Yeah the algorithm finally likes me, lol… glad it found you!

[@jerbear7952]

Hmmmm. They have actually built something though. Maybe you shouldn't laugh at them.

[@WhatDadIsUpTo]

Liked & subscribed. That said, I wish you had less-verbose "shorts" for the several techniques. I'm autistic and tend to over-explain too, so I really have no right to complain, but brutal honesty is also an autistic trait; sorry.😢 I'm skinning with (0.040?) Aluminum sheet, so I have "other" issues. Thanks for your time & effort in creating these videos.

[@LifeAtTerminalVelocity]

I'm watching a ton of these type of videos before I build out my truck camper and let me tell you that this method is freaking amazing. So far the best I have seen. Thank you for putting this out.

[@falkornomad]

My pleasure!

[@secretsquirrel6308]

I discovered for myself the idea to use foam sandwich (fiberglas cloth on both sides) for stringers in boats. So far, absolutely no problems. The benefits are great. I mention this to emphasize the rigidity of the sandwich is very satisfactory. It withstands the cyclic pounding and vibration in boats.

[@falkornomad]

👍🏽

[@solgerin4christ]

@@secretsquirrel6308are you using fiberglass Rosen with your glass cloth?

[@fishypictures]

Aside from your craft abilities, I am impressed with your speaking and teaching skills. I am a public speaking student/ teacher ( you never graduate) . You stay natural, focused and speak extemporaneously, you seem comfortable within the topic. Very good. You have a unique skill in camera presence using gestures both visual as well as vocal. You also have a sense of humor, very critical when keeping your audience engaged. Just thought I would let you know how well you speak to an audience. Great timing for me, just so happens I’m starting a camp van build and is why your video caught my attention. Thank you!

[@jacquitabeddo6621]

Wow I'm so impressed with how meticulous you are about sharing all the things that can help others succeed with this building method.

[@falkornomad]

Thanks…. But honestly… to me… that’s like the best way to use KZbin… sharing info and ideas as much as possible.

[@lpon9757]

That's better than a paid training, so much information and insights in this video. Thanks for putting so much effort into this!

[@falkornomad]

Well, technically you did pay, but watching a few ads is pretty cheap 😜

[@GOLDVIOLINbowofdeath]

What paid training?

[@GOLDVIOLINbowofdeath]

Your way of doing the economics is weird and ignoring the weight of the doors is absolutely cheating. PS, nobody is using plywood for insulation and insulation not on an outside wall is pretty irrelevant. Also wood everywhere is not the only choice so unfair comparison, so basically you make strawman arguments for your method vs anything else.

[@GOLDVIOLINbowofdeath]

1/4” partial board won’t hold that water tank in place in a front end collision and all that water going all over the van is going to destroy the entire interior and possibly cause your lithium batteries to catch fire.

[@GOLDVIOLINbowofdeath]

What’s in the fumes that off gas when you cut this foam with a hot knife?

[@ayanaali546]

I was sold at the mockup part. The fact I can see and get a feel for how the build will work before everything is permanent is amazing 🤩 ‼️

[@arthurwieczorek4894]

I only watched seven minutes of this video. I've given this guy a thumbs up. He is a great communicator.

[@annepeterson1450]

Holy crap dude, this is freaking BRILLIANT!!! We’ve got an old pop up camper I’ve been thinking of selling instead of fixing it up but honestly, now all my crazy ideas of how to modify it are completely doable! THANK YOU FOR THESE VIDEOS!!!!!

[@falkornomad]

👍🏽

[@travisgray1099]

Man I seriously appreciate all the work you have put into getting your experience building with this material out to us! I’m going to be using this method in a upcoming flat bed camper build. A video on drawings and mock ups would be awesome. Always great to see more content from you🤙🏼

[@falkornomad]

You got it… I’ll see how soon I can get the drawings & models video out for you.

[@creature7310]

I built with milk crates, fabric cube boxes, zip ties, and winch traps. No plan, just Feng Shui all the way.

[@nomadmusk]

My mind right now... blown. I had no idea this was a thing, and will be super critical for my electric van build.

[@SonoranSpaceProgram]

I appreciate all the time and effort you've put into R&D of this building technique. Super informative video and I will definitely be watching the full series!

[@falkornomad]

Cheers!

[@lucianoandjoannasoares9286]

Literally the best DIY KZbinr I have ever seen. Most people are trying to be cute for the camera build algorithm, not give real research or facts to anything they say so no one has any real idea what to do. Thanks so much.

[@avalonunitygarden2394]

You have been an inspiration for me for years! Thank you for all your research, quick explanations. Glad to see you again on YT. Thank you for making fantastic informative videos. Many blessings

[@GooseTheFlick]

I'm blown away by the practicality of this.

[@heyjude5759]

Mind Blown! This is the first I'm hearing about you or this building system and I'm beyond impressed!!! Thank you SO much for the amazing amount of knowledge, experience, and passion that you are sharing with us!!!

[@falkornomad]

You are so welcome! You might like my first video as well.

[@wrathofsocrus]

Great to see a new video series! This is fantastic info and very well laid out. The 3D drawing and mock-up stuff is really important. It's very easy to design a bunch of 2D stuff, build it, and find fitment issues after it is too late. I've used cardboard in the past, but if you are already building with foam then it makes perfect sense to try it out and see how it will work when put to use. I know this is a lot of work to put together and it is greatly appreciated!

[@falkornomad]

Thanks for acknowledging how much work video production is!! Glad you find the content helpful and easy to consume… it’s a battle to find the balance.

[@user-zt4gt6vf6f]

You are the man! For doing all this and sharing it for free.

[@dar4835]

Thank you for your time, effort, and humor in this video. The ingenuity is phenomenal!

[@returningtoearthtv8836]

I am beyond stoked that you are back on the KZbins sharing your FomBonz wisdoms. Your information is clear, concise, and all-pro. Your presentation style is fantastic and your creations - superb. Muchas Gracias from Oregon. This might be coming in a future video but I would enjoy learning your system for cutting accurate mortise and tennin/plunge cuts. I have struggled with this.

[@falkornomad]

You can make a jig if you want more accuracy, but I just roll with it and fill with a little extra glue.

[@zachvalenti]

This is awesome. I never would’ve have imagined this material for this use-case! Way to innovate in this space.

[@falkornomad]

Thanks, more innovation to come (not just foam building) in future videos

[@SkooterBrother]

When I finally realise my dream of living in a van I will no doubt use your techniques. I just hope the videos will still be avaiable in ehh few years time. Great videos, very inforrmative

[@luisaraujo4708]

Genius! I’m using every bit of your system to build my pontoon boat boathouse where weight is critical to the finished build. I’ve been racking my brain over the how-to aspects of lightweight construction and the literally tripped over your channel. Thanks for the in-depth work you’ve done and shared.

[@workinprogress5821]

I think this is the most clearly explained, detailed video I've seen in a long time. Thank you.

[@falkornomad]

Thanks! It’s a work in progress 😉

[@paulaarchuleta8684]

WOW! I love it, I just to work at a sign company and we used form and plastic ALL the time. Them stand-up to ALL elements out/ inside and the installation element makes a lot of sense.

[@falkornomad]

👍🏽

[@strawberryroad1347]

So glad I came over this video. 😃

[@Lupgaroo666]

Excellent! One of the best instructional, explanatory, presentations I've seen. Great job!

[@placestosea]

thanks for posting, its always interesting to see lightweight options for van builds. we opted for another non wood option.

[@falkornomad]

You’re welcome

[@WisconsinWanderer]

Wow it’s been a while watched your cabinet build years ago and cement floors in the barn. Glad you’re doing well my friend 😊I’ll stay tuned ☮️❤️

[@falkornomad]

Thanks 👍

[@mhzprayer]

This is extremely well outlined and well spoken. Very interesting and thought provoking. The inset videos while sitting next to them and explaining what's shown is very well done!

[@jakemackenzieblack]

I just want to say that I deeply appreciate your methodical and organized approach to teaching this. You gave excellent examples and highly detailed instructions, definitely inspired me to use this system on my build. Great work!

[@NomadicBillyGoat]

Glad I met you in New Orleans! You definitely inspired me to rebuild my van, utilizing this foam bones method! Thanks for sharing! I'll be sure to credit you with the idea! Can't wait for the next part of this series!

[@falkornomad]

Good to hear from you! Sorry I inspired you to do all that work, lol. I am talking with another viewer about using FRP panels rather than wood, might be something you’d be interested in looking into.

[@NomadicBillyGoat]

@@falkornomad Absolutely! No worries! I wanted to cut down on weight. It's a great idea to work with.

[@starr_ship]

A true DIY king! This is a brilliant, and even though the concept may be old, this guy shows just how incredibly versatile (and easy) this methodology really is. The amount of data compiled to prove this out is nothing short of beautiful. I can think of 8000 ways to put this to work outside of a van, and I'm going to start by building my son some modular fort elements so that he can mix and match new forts as he sees fit.

[@falkornomad]

Love it!!! Foam Fort Activate!!!

[@user-ro4ns7qk1s]

Thank you Sir and GOD Bless!!!

[@pjglory3348]

I am thrilled! A real breakthrough in making van builds accessible for me!

[@falkornomad]

Glad you are inspired… not my invention though… I stand on the shoulders of giants.

[@didiwin78]

Very nicely done! I had envisioned this years ago and im thrilled to see someone has done it! Imagine this project except your doing it commercially; take 3d scans of the inside of the vehicle, do 3d cad models from the scans and make cut patterns for all panels, including the wood, get a laser cutter that fits 4x8 sheets and easily cut all the needed tabs, with labels to simplify assembly, the glue up goes smoothly, hopefully, on account of the 3d scans and it just needs finishing touches and equipment install to be totally functional. Imagine the potential speed of prototyping and freedom of style if the build style and quality is standardized!

[@falkornomad]

Yeah! When I first saw it in 2010-2012 I thought it had much more potential than what was being done. Then my prototype in 2013 (see my first video if interested) proved to me that there was MUCH more potential in the idea. Absolutely a 3D scanner and laser CNC would be amazing… I’ll ask Santa and YT ads to buy me those! Lol

[@rosalieroku3818]

Fascinating technique. Not unlike a small scale SIPs (Structural Insulated Panels) which is also an excellent method.

[@falkornomad]

Similar for sure

[@cesalt2408]

What a tremendous contribution to the self build community. Thank you so much!!

[@falkornomad]

You're Welcome!

[@Voltermort]

What an absolute wealth of knowledge. Your research and design is advancing a whole movement. Appreciate your work.

[@m0nkm0de]

looking forward to this, skinned foam is a wonderful building method

[@falkornomad]

I think so too!

[@rafaeldye]

Dude this video is brilliant! Good work man baffled why this doesn’t have 100x more traffic

[@falkornomad]

See my first video, 5 yrs ago… I used up all the magic back then… I’m not here for the views… glad the content you liked found ya!!

[@CheekyMonkey1776]

This guy is a genius

[@falkornomad]

Not a genius!

[@nednobody3253]

On of the Greatest most Understandable Presentations I have personally sean on the internet. I'm fixing to do another van and you have just changed and simplified my whole project. Thank You...😎

[@globaldemise]

I haven’t even watched this video yet and I already know what your going to do is going to be amazing. I have been using foam and foam glue for all sorts of things over the years and it’s amazing

[@falkornomad]

Well… if you saw my prototype video from 5years ago… or my tour video from 5 months before this video came out… you’d be cheating… but I guess you just have confidence in foam and bearded man 😜

[@ericensley2427]

Love the Lebowski references :) Lots of great stuff.

[@falkornomad]

👍🏽

[@jerbear7952]

He needs a rug to tie it all together.

[@falkornomad]

@jerbear7952 lol, it actually has a rug since one of our dogs has a leg injury and can’t stand on the vinyl flooring very easily… however it’s “tying the room together” skills are very week. Fortunately, no thugs have pissed on it yet!!

[@Star08273]

this is absolutely incredible

[@chizkiyahukabas7078]

Thank you very much for this video and your channel ,I have never known just how these builds were actually put together let alone with the foam genius

[@pauljconroysr4080]

Love Your Videos been watching for a long time and glad to see you going strong Brother :) ! Rememebr when you did the map lay and as well as standing on the boxes ;)

[@falkornomad]

Thanks for that!

[@gregbowl2426]

As I've been watching some videos on builds, and horrified by the use of heavy materials, I like your approach. I'm less inclined to see cost savings, which is good, but weight savings as the goal. I'm a big fan of Nomex core board used in boats, and Okume ply for its strength and waterproof glue. (I split my time between liveaboard sailboat and "Land Yacht") Keep up the good work.

[@amunderdog]

I was thinking similar. This is a good idea, Taking it to the next level, would involve fiberglass and epoxy. To finish with paint or a veneer.

[@falkornomad]

You all do you all, but… why is everyone so into fiberglass? Seems unnecessary, messy, itchy and dries hard and brittle rather than flexible.

[@kpuliatch]

Well Done ! researching and improving your building with elegant solutions . Much Gratitude

[@davefletch3063]

I am always amazed at how useful this foam is for many projects

[@falkornomad]

Yeah… the possibilities seem endless… and I want to do them all!!

[@howard6798]

Awesome content! I watched your original video some time ago, so thrilled to see this follow-up posted. I'm looking forward to the rest of the series. I am curious if the system will adapt to exterior spaces. I'd really like to figure out how to build a custom truck bed cover using foam as the primary component both for the easy customization and the weight savings. (It will cover a motorcycle I tow in the bed of an F-350.)

[@falkornomad]

Thanks for sticking with me! Foamie Trailers are what you should be looking into… it’s basically the same thing you’re thinking.

[@I.m-Me]

I appreciate you sharing your efforts! The _CheapRVLiving_ channel, (which spawned HOWA, the Homes On Wheels Alliance,) is all about sharing ideas and help, especially for people on a budget, so I am certain that they would love to interview you in person or virtually and give your channel a boost, so I would recommend communicating and coordinating with them directly. I also think that you might enjoy their content and the community they've fostered.

[@gettingintrospective]

I just thought Bob needs to see this and share it with new van lifers

[@I.m-Me]

@@gettingintrospective I'm currently spoonless, but if you've got the energy for it, please do contact them!

[@gettingintrospective]

@@I.m-Me spoonles?

[@I.m-Me]

@@gettingintrospective Essentially, 'too tired' or 'reserving energy for other tasks'. Search "spoon theory" for a better explanation. It's not the only way to think about things, but I have a lot of disabled friends, and it's widespread enough to be common parlance among them

[@falkornomad]

Thanks for the info!

[@samwheelock9743]

Great info and disclosed in a fashion which is clear and credible... thanks

[@czthor1]

Informational, I will follow this on my build!

[@orcoastgreenman]

Great video! One choice I would have gone inverse of what you chose was your backer materials for the electrical and plumbing hardware mounting. Real plywood will suffer much less damage from incidental short term water exposure than even melamine covered particle board. Though if it was a matter of what one had on hand big enough to use for each task, I would just go with it, as the particle board is cheaper to replace, if it does get water damaged. One trick for mounting things in particle board, is to pull your screws and squirt some drops of crazy glue in each hole, let it dry for 5-10 minutes, and screw them back in. Will soak in, and turn the particle board around the screw, into a VERY hard plasticized composite, and it will be 10x harder to over torque it and spin it out.l, or for it to pull out, from the weight it is supporting. I use a medium thin cyano-acrylate, usually super glue brand from the dollar store... to repair particle board furniture, and reinforce the rotating cam holes, and screw holes, in the particle board when assembling new flat pack particle board furniture, and it makes it significantly more durable and reassemble-able.

[@falkornomad]

I did have this melamine on hand. When I screwed into it I went through it and into the vehicles cladding, but good tip!

[@jerrycampbell1515]

Awesome idea. Got another that could help with anchoring. Make up small wood blocks and insert them into the foam. This would give you wood to anchor into and the blocks would disperse the load a lot better then the small screw tabs. Could even do them on the front of the boards to attach your cabinets facing trim.

[@falkornomad]

Yep… lots of options along this line… following the glued in anchor down the rabbit hole for science👍🏽

[@battshytkrazy156]

ALUMINUM... plauzibly plastic az well

[@randolphrobinson342]

Foam Bones!! This the # 1 best Rv/ Van rebuild mock up and design video I have ever seen. I have worked with foam for 30 years. Exterior foam.😮 you made me smart again with foam. I have a 28 foot 1984 Leo Craft … my imagination is going. Thank you for that!!!!😅

[@falkornomad]

Thanks… that’s quite a compliment, hopefully the rest of the series/ this channel lives up to a fraction of that compliment.

[@kevinkemble3718]

You are a fantastic innovator! I’ve used similar processes. In fact building a secure “system” to keep a vehicle in. Thanks for your time!

[@falkornomad]

Cool, thanks

[@packadip1]

Very informative, thank you. Eagerly awaiting Vol 2 with alternative adhesives. I'm mostly convinced Glidden Gripper does not exist in Canada.

[@falkornomad]

Any heavy duty primer… really any paint is fine

[@grahammonk8013]

I have found two products you might want to experiment with, STIX, and SUPERSTICK. can't say how well they work yet, but a couple of small tins will allow some trials.

[@unimog404]

Great video and explanation! I love people they really think about a concept and not just copy what others do. I choose wood because I like it as a material. And I come out of a woodworking family. I used some birch plywood and I don't like it way too soft. I choose Okoume plywood 😍

[@falkornomad]

Glad you liked the video.

[@jjfink3925]

These foam tips can be used for many things, great video

[@betsyandall]

"He's Mad, I tell you!" Excellent video. Thanks!

[@kennethquinnies6023]

I have concerns about the vapors almost all foams give off

[@JonValtandtheEvilRobots]

They use this same stuff in houses

[@debstraub8437]

Love this awesome video! Great details, great humor, and great editing. I love that you pulled out the spreadsheets… right up my alley. I’m obsessed with economical ways to build well-insulated homes/shelters. This gives me so many ideas! Thank you for the awesome video😍

[@falkornomad]

👍🏽

[@gordeng4001]

I have learned more from you on foamies then any other videos I've watched PERIOD! And I have watch several on KZbin. THANK YOU, THANK YOU, THANKS! For all your hard work and knowledge sharing!

[@falkornomad]

My pleasure

[@mikel5140]

I appreciate the work you put into all of this and sharing to such a level of detail. I hope to attempt some of these techniques myself. Well done and Thank You.

[@wnccody]

How am I just now finding your channel. Finally found someone that makes cool useful things in an economic and smart way

[@vinniedimodica8705]

Thank you for this excellent series or recap on the build and system. This will save me tons of hours and time. I can now watch a few hours of videos and not repeat things that you have learned or improved up on. I can use my time doing more of the building process and less experimenting. I like the time and weigh savings but really like the R5 insulating factors. This will save me 100 of lbs of weight. I like everything about this so far! Very much a motivating and encouraging can do plan with little worries of wasting materials on a mistake or two.

[@NoteFromSELF]

Thumbs up instantly for the table of contents. 🏆

[@borregoayudando1481]

fascinating... this is building with basically those puzzle fit foam yoga mats. Never knew it could be taken seriously but you took it somewhere. Bravo.

[@BretRoebling]

It seems like I have been looking for years on materials to use for a van build out. I have looked at the deck system, another one that is pre-cut out plywood system, and this one by far, has got to be the best design process and material Video that I have found. Thank you for all of your research and development. I am now following you and sharing you with my other van friends. 🎉

[@falkornomad]

Rad! Thanks!! that’s a big compliment, more to come on all fronts!

[@OutlawToys]

Thanks for sharing your experiences and findings.

[@falkornomad]

👍🏽

[@artofpootan]

You explain it well! No beer necessary to appreciate all the painstaking detail and math involved. You just saved some people a lot of money and frustration.

[@falkornomad]

👍🏽

[@kevinkyle384]

What a great idea!! Thanks for sharing!

[@MichaelNatrin]

This is incredibly informative. Thanks for sharing.

[@russelturner8691]

Awesome job looking forward to watching the other videos .

[@lrrp25]

Incredibly detailed useful information!

[@CMD82]

I have an old RV that I need to reno in order to leave out of it later, and I am going to use your tips and tricks to do so in a way that will get everything that I want, from R-Value, to customization and building that is easier for my disabled self. Thank you for the awesome content.

[@eleanorcramer7986]

I am feeling lucky about finding you and your genius. I will be networking this rich resource with excitement, inspiration and hope. This deserves being brought to the forefront due to its myriad of benefits for doing - it- ourselves. Thanks and thanks again.

[@bormatnor]

Been following your project and looking forward to the rest of your project. Actually I am glad I found your work because with the project I'm working on you have given me answers to some of the problems I'm thinking through. Keep it coming I'm invested.

[@falkornomad]

Glad it found you! 👍🏽

[@HackxBox]

It's amazimg how analog this systems is, yet it has the features of modern building techniques. Great job and thought and research you've put into this.

[@falkornomad]

👍🏽

[@robertleon1195]

Love this idea - I'm in the research phase of my first vanbuild, and found this video. Well thought out, excellently presented, and superlative knowledge transfer - thank you!

[@Roobah]

I have been waiting for these videos for 5 years. 8 loved your original insulation and foam build videos. This video popped up in my suggestion feed, so I guess your shares are working.

[@falkornomad]

👍🏽

[@jimbaranski4687]

Your videos are freaking AWESOME! The subject matter is novel; your video editing is flawless, superb included graphics; your narration is smooth. I'm just amazed six different ways by your videos!

[@falkornomad]

Thanks!

[@orenmontgomery8250]

I just saw this video and it made me think of my war gaming terrain builds. I used xps a lot, even built shelves or of it and found it was SO much stronger and stiffer even with a little ModPodge brushed on. Camper vans really intrigue me and I already have an affinity and equipment to deal with foam, so this is great.

[@falkornomad]

Yeah!!! Then combine the two disciplines; build a van and foam sculpt trim like you do terrain… I had a hole for making trim to look like branches supporting all my overhead cabinets… maybe next time.

[@orenmontgomery8250]

@@falkornomad awesome. 👌

[@neeceespielman4834]

Thank you for all the work you have put into the numbers. You have taught me so much. Love the screen glued to the foam idea is genius!!

[@falkornomad]

👍🏽