I'm building a truck camper out of foam? (Yes! And it's going to be beautiful!) Ep. 2

[@PA96704]

After building a few boats and and an aframe cabin. I am mind boggled that no one has built one out of foam yet. Good job!

[@GeorgiaAstronomy]

Thank you!

[@nomadterry6146]

​@@GeorgiaAstronomyhow has the fism camper lasted.

[@returningtoearthtv8836]

Hello! Nice job on your build so far. It looks light and strong and well thought out. I too am building a foam camper. It is for my Nissan Atlas - retired firetruck from Japan. It has a flat bed with drop gates, no wheel wells so I have created a cube camper that is slidable-inable and outable onto a sawhorse table I built. I found inspiration from KZbinr “NOMAD” who has done some incredible stuff with XPS foam, bug screen, coated with thick paint - like a light weight fiberglassing-ish technique but his stuff is just for cabinets and furniture inside his vans (one VW bus, one Sprinter). I also borrowed heavily from KZbinr “EndGame” from whom I got the idea to build a lightweight post and beam frame for my cube and then filled the voids with XPS and then fiberglassed over the entire thing. From “NOMAD” I learned about Hotwire Foam Factory who make powerful foam cutting hot knives and also produce this incredible glue called “Foam Fusion” which I have been using to glue all my foam into place as well as for laminating the outside of my cube with 1/8” ply before I fiberglassed it (two layers of 9 oz cloth) and then painted it with white bed liner. I have also been embedding wood in various spots on my build where I know I will be placing tie down anchors for gear on the interior, as well as wood pieces to anchor my future furnishings (bed and benches). Your fiberglassing I think is thicker and stronger than what I have done so you might be just fine anchoring directly into that thicker skin. I have been using those threaded nut insert things that I can screw bolts into. Not sure if that makes sense. Anyhoo, I wanted to mention “NOMAD” and “ENDGAME” to you as those fellas have some creative ideas and are both crafty as hell. Take it easy. Enjoy the process. Light is right. I’ve forgone many things that some people seem to think necessary in a camper i.e. no shower, no sink, no plumbing. Just a propane stove, a Bluetti ac200p, a 200 watt solar panel (attached to a Packasport roof box) and a Yakima road shower on the rack above. The rack is anchored into wood beneath the fiberglass skin. . . That’s enough… I could go on. Cheers!

[@GeorgiaAstronomy]

Yep! I took inspiration from Nomad and Endgame as well! They do some incredible builds!

[@lightfeather2439]

Yes! I have been looking for this type of design forever. I really hope this camper lasts a long time. I will probably borrow this design and hope you post more videos. Thank you for your good work.

[@GeorgiaAstronomy]

Thanks Light Feather. The camper build and other projects were moved to Georgia Builds One on KZbin. I needed to keep the projects separate rom the astronomy channel.

[@mikekupetsky6879]

😅 0:19 😅 0:19 0:19 😅

[@mikekupetsky6879]

0:19

[@lightfeather2439]

@@mikekupetsky6879 I don't get it?

[@edwardharrison9714]

I thought of building 1 like EFS. With, densglass, foam ,base mud, mesh,, texture and then elastomeric..

[@mountainman4410]

I putting a flatbed on my truck first. Then building the foamie camper. This way my floor space is more open.

[@Verb130]

If you look up fiberglass wet foam layup construction for aircraft, you do not need any special joinery for gluing foam together. You could have saved a lot of time and done a simple "butt" joint glued with flux (epoxy and flocked cotton mixed) to hold its form. The strength of the join will be in the fiberglass cloth added as a wet layup. It's the fiberglass on the foam that carries the load across the joint, not the foam. I recommend you look up Burt Rotan's videos that show the complete wet layup techniques used in his aircraft's designs.

[@GeorgiaAstronomy]

Thanks K Verb! I'll check it out.

[@nazufani4016]

Thank you very much for the info you imparted. I have been watching vids about this construction technique......cause.....I got a bus.🙃👍🌻

[@racrx7]

@@GeorgiaAstronomyI disagree with NOT using box joints, aka finger joints, with the initial construction of “box store foam” construction. I use it on smaller projects and it makes for a more rigid and structurally sound connection in its raw state of construction. You’re using box store foam and NOT specialty foam like Divinycell type foam used in aviation and marine applications. Keep doing what you’re doing. Looks great so far.

[@rogermccaslin5963]

@@racrx7 I'm a little late to the party but I thought I'd throw in my two cents on the subject. I used to build fish boxes for commercial fishermen out of 2" foam and fiberglass. The basic recipe is as follows: Cut the foam to size. Pin the parts together with 16 penny nails. Round over the edges. Glass over with three layers of 1.5 oz mat. Yes, there is a little more detail to it but those steps are the basics. We never did anything other than butt the pieces together and never had an issue. If you know anything about commercial fishermen, you'll know that they aren't exactly dainty when it comes to handling their equipment. Can you use box joints? Sure, but it's my experience that they aren't necessary. When you pin the foam together, run the nails in at slightly different angles and the parts will stay in place. The boxes I built were usually about 48" x 48" x 30-36" tall so not small by any means. We would flip them from side to side as we glassed them and never had any problems with the pieces coming loose before they were glassed.

[@glenb1356]

You might try foam fusion glue. Also, Gorilla clear glue is good but expensive. Finger joints are not necessary. I would have put a radius on that inside step joint for the fiberglass. You need fillets on the inside corners and round edges on the outside corners. I have made quite a few things out of foam and fiberglass, great material!

[@gordondurkee7612]

If you radious your corners you'll avoid air bubbles, that glass doesn't like square corners, just saying , I'm not knocking you it's just a suggestion.

[@GeorgiaAstronomy]

@gordondurkee7612 I tried to round most corners, and honestly, could have been even more rounded than I did. It was minimal at best.

[@holmes1956O]

Thats not a suggestion it is how the professionals do it. Radiused corners are the proper way to get 100% bonding in both inside and outside corners

[@racrx7]

One thing I didn’t hear mention of is the type of fiberglass cloth being used with epoxy resin. Polyester type cloth fibers use a polyester resin to temporarily hold the fibers together until the application of the polyester resin which melts the fiber binding poly for a complete cohesive bond of the two materials. Epoxy resin will not dissolve the poly binders in the cloth. There are special cloths made just for epoxy resins where the fibers use a type of powder to hold the fibers together that gets absorbed in the epoxy. If I missed that you are using glass material for epoxy, my apologies. On a side note, I’m liking the the thin ply over foam coring method. Kinda like the I-beam principle.

[@GeorgiaAstronomy]

@racrx7 Its standard cloth, not poly. You are correct in that poly needs poly to dissolve the binders. However, using polyester resin will melt the foam.

[@noncched6839]

I could use this method to make an extra large ice chest.

[@GeorgiaAstronomy]

It would stay cold!

[@nickhamm1621]

Hey Guys. I am now out of Malawi and in Canada and can finally join you guys live. I am just looking at a picture of Richmond Webb and Keith Sims I think their rookie season at a Buffalo game. Thanks Richmond for the memmorries.

[@kdrapertrucker]

It occured to me early today I could build a pmf/foamie truck cap for my Kei truck.

[@GeorgiaAstronomy]

We had another individual do that for his Tundra, rather than full camper.

[@AstroLanderRV]

Looking very solid! Nice work 😎

[@GeorgiaAstronomy]

@AstroLander Thanks!

[@davidlindquist3113]

Excellent! I’ve been thinking about doing this too.

[@orcoastgreenman]

I believe the kingspan foam is likely 25 psi. That’s what the Owens Corning pink foamular 250 is.

[@GeorgiaAstronomy]

Yes. You are correct. Word jumble and scattered thoughts! :)

[@TRUECRIMESPTV]

Use pin nails to hold your foam together as well.

[@patrickmckowen2999]

Very nice👍 I am thinking that since most of the strength is from the FB or CF shell that will be applied - I was was just going to glue the foam edged on edge then drill some holes and put some dowels and glue in them for a little extra working strength. Cheers

[@GeorgiaAstronomy]

@patrickmckowen I was considering the dowel method originally as well until I found the video on the guy doing a notch method.

[@mlangfordoutdoor]

hay Patrick how are you brother

[@SuperJellicoe]

Dont over think the construction. It is not a space shuttle! It will be a canopy or a camper travelling at less than 80 mph.

[@marleneandlarry]

Great videos explaining the process. Do you know how much your unit weights? Thank you for your time.

[@GeorgiaAstronomy]

@marleneandlarry Thank you. I covered in episode 18. It weighs 440 pounds!

[@marleneandlarry]

@@GeorgiaAstronomy I will definitely watch them all once my grandson and I decide on the a plan. A truck camper will be prefect for going fishing over night. Thank you for replying to my question.

[@virginia_in_the_rearview]

This is amazing! I'm actually building out a Shuttle Bus into an RV, and your explanation of how you did the fiberglass was perfect for me! I don't know (yet) if I'll need to do any fiberglass repairs, but with your explanation I see no reason I can't do it if needed. Can't wait to watch the rest of this series. I'm hooked!

[@GeorgiaAstronomy]

I am SOOOO jealous!! That was my first thought as a shuttle bus conversion! They are perfect! Are you videoing?

[@virginia_in_the_rearview]

@@GeorgiaAstronomy No, I'm not videoing. I am taking pics and will put together a video at the end though. My son goes off to college next Fall, and I should be ready to hit the road then.

[@GeorgiaAstronomy]

@@virginia_in_the_rearview are you going full time #vanlife?

[@RoadKing05FLHR]

I am considering a build for my f250. This is what I'm not understanding. With all truck campers the floor is so narrow, like 48". This results in a lot of weight being high. Why not build it the width of the bed with cutouts for wheel wells? My truck has a long bed so I talking about a lot of space down low for tankage, storage, room for shower and toilet, refrigerator with room for other heavy storage underneath, etc.

[@GeorgiaAstronomy]

Couple of guys have built their's as truck 'toppers' but full height. I did play around with the idea of allowing the rear to pushout the sides, aft of the wheel wells, to allow extra storage room and only have the front part narrow for the wheel wells. Alas, I didn't go with it.

[@tuckerandi]

Plannng on doing something similar so I've subscribed to follow

[@dalecarpenter8828]

Foam and fiber glass !

[@jamespolucha8790]

Very nice job I think I’ll try this for my tacoma,thanks for the videos

[@Spacecarboy]

I'm impressed. Do you know yet what dry weight will be, and will it have a wet bath? Should have good structural integrity. Tony

[@Spacecarboy]

Estimate on the weight, obviously.

[@GeorgiaAstronomy]

Hi Tony. On paper, its says around 900 wet weight. I have my doubts though as it is easily moved around at this point at 85% complete. I can still lift the corners as well. There is no wet bath on this build but only because the couch/bed is in the tub. With everything I have been learning on this version, it has given me ideas for the next iteration for when it is cloudy for 5 months straight! :)

[@benc7102]

G’day CJ Looking good mate!!

[@GeorgiaAstronomy]

Thanks Ben!

[@tacomaastro7462]

Hydroplane racers use the West systems, the difference... they vacuum cure it.

[@GeorgiaAstronomy]

I definitely plan on bagging the next one. Laying up the fiberglass hasn't been hard but it doesn't obviously saturate 100%, as I've seen bubbles here and there. Lessons learned already!

[@felixcat9318]

What a really well considered build this is, in addition to good videography and narration, making it an excellent tutorial, subscribed. I particularly liked your method of attaching the panels together, you've greatly increased the contact surface area and the strength, fully reinforced with fibreglass fabric and fillets. The plywood protecting the tub and being itself fibreglassed was the icing on the cake! This is very impressive and inspirational, thank you for sharing your excellent build.

[@GeorgiaAstronomy]

@FELIXCAT thank you!

[@russellesimonetta9071]

Uhh, if you coat the foan on both sides with epoxy glass you would have stabile strong material to cut and assemble. Good idea with the finger joints. To join panels use epoxy and wood flour mix. To sheet the panels coat in a thin epoxy micro balloon mix then just lay it down wet out and bob,s your uncle.

[@tireballastserviceofflorid7771]

The fiberglass is called either chopped strand mat. Or continues strand mat. The vast majority are not compatible with epoxy. There are some different types of sizing used. Check what kind before you use it with epoxy.

[@twohandsworking896]

Saw a guy on KZbin build camper out of foam ,then sprayed it with stuff they make yeti coolers with-we all know how tuff a yeti coolers are-ive seen a few fall out of the back of a pickup-no damage

[@mundodebandeirante]

very good your videos. I'm building a camper and the information is very important.

[@GeorgiaAstronomy]

Thank you! Glad it helped.

[@melyssabailey8935]

the interlocking method you used to join 2 foam boards together is called a dovetail which creates a very strong joint. What kind of adhesive did you use on the dovetail joints?

[@ahowl7mx]

I want to do this with a cargo trailer conversion

[@GeorgiaAstronomy]

Just started a cargo trailer conversion. Not doing foam core though, this time.

[@ahowl7mx]

@GeorgiaAstronomy Look forward to watching the design. Been looking at examples for the last few weeks and have a top 3 if you're interested in ideas.

[@warrenmcmurray121]

Could the camper be longer and built to rest on the tailgate?

[@GeorgiaAstronomy]

@warrenmcmurray121 Yes it certainly could be!

[@Stepanhuge]

Hi! Incredible project! I am looking all the videos!! My question is... why did you use epoxy and not poliester resin? Poliester resin "eats" xps?

[@GeorgiaAstronomy]

Thank you and thanks for watching! Yes, polyester melts ups foam.

[@-joe90]

Super!!!!👍🏻

[@GeorgiaAstronomy]

Thank you! Cheers!

[@danhelwig]

Watching your jig notching expertise, why not dovetail these joints?

[@Stevesbe]

Nice tundra sorry about your mpg

[@Hipporider]

I heard on another foam camper video that having the floor as foam will result in compression and the floor will crumple. Have you a work around for this? 🇦🇺

[@GeorgiaAstronomy]

I'm sure with a considerable amount of weight, this could occur but since it was wrapped in fiberglass and only weight on the top is walking around, I do not see it as an issue. The bottom of the tub does have a sheet of 5mm plywood under it, also fiberglassed into place.

[@melyssabailey8935]

the compressive strength of the foam board insulation is about 20psi

[@batmanwatchmanwatchman8113]

Hey thanks for the video! any chance you have an estimate of how much epoxy which would be need for your project?

[@charlesjohnson9035]

Hey GA! I combed through your comments and couldn't find any question covered, so I'll just ask. At the beginning you showed a view on a CAD program. What software did you used?

[@GeorgiaAstronomy]

@charlesjohnson9035 It is called sketchup.com

[@mlangfordoutdoor]

And no I had a 2008 with the 5.7 it was fun to drive but like riding a bicycle on a rail road track and 12 mpg I just could not afford to keep it so no it was rehomed

[@GeorgiaAstronomy]

Gas mileage is horrid!

[@patrickheath5011]

Very nice. What is the tool you're using at 4:25?

[@Constitutionallycorrect]

Just don't spill any gas on it. Gas and styrofoam make a very explosive mix

[@dmw83831]

Could of glued it together up side down , would have a better level standing

[@gerlandkent6377]

[thank, you for you're video I, like you're plan]👍

[@TJcamper-u8b]

I made a simple trial

[@GeorgiaAstronomy]

How did it turn out?

[@joec7325]

What do you use for the Foam Glue?

[@lawrencefranck9417]

What did you do about the double cut at 5:00?😂

[@GeorgiaAstronomy]

Started a new piece and used the bad one for other parts of the camper.

[@acme511]

How many gallons of resin should one order?

[@GeorgiaAstronomy]

@acme511 5 gallons. Its cheaper in the long run.

[@CarolinaCarolina-ph9mx]

Hi, sorry to bother you but I was hoping you see this and could answer a few questions. I am a newbie to foamie building, but I am very interested in it, and I like that the building materials are lightweight. I am seriously considering helping a family member makes something like this, so plan to watch your series and learn as much as I can. At 10:40, after you had sanded the glued joints, you appeared to glue a wide strip of something down across the joints. What did you use there? Is that the fiberglass you were talking about? You later said you were using "17.08 Fiberglass" (is that what was used first across the joints also?), but I looked for that item on Lowe's website but nothing came up, so I am not sure what product to use for this item. Sadly, you lost video when you turned the box over, but if I understood correctly, what then happened was that you squared your box, then glued 5mm plywood to all areas on the outside of the box. Then you probably sanded down the edges so they were smooth, then you glued that fiberglass stuff across the joint edges once more, and then when it dried, glued the fiberglass (cloth???) across the entire outside of the box. Then you sanded over it all to make it smooth. Is that correct, or did I miss something here? Did you wear googles and a mask to protect your eyes and lungs from the dust when you were sanding? I have seen a few videos that briefly mention the use of some fiberglass product in foamie builds, but isn't that somewhat similar to the fiberglass insulation that is bad for the lungs? If so, is there a good alternative? Also, at 13:41 there is a blue strip on the inside of two joints. What is that? I have watched a few videos from Nomad (plan to watch more), and he did a test on 6 different types of adhesives. He found that the glue strength of Gorilla Glue Original was the best, and then the Gorilla Glue HD Construction came in second. You chose West Systems 150 epoxy resin. So I'm guessing Gorilla Glue (either type) doesn't come in bulk for projects such as this, or maybe there is something about using it in this manner (the outside of the box and not the interior) that makes the epoxy glue you are using the better choice? If you see this, appreciate any answers you can provide. I am impressed that you were able to build this camper yourself. I've watched a few of your videos already, but I started at the end first to see if i wanted to watch the series (I do). The total weight of your camper is amazing. The cost was higher than I had hoped, but still much, much cheaper than buying a new camper, and yours is probably as durable if not more, and definitely better insulated. I can likely find a few ways to reduce some costs, then add other items over time, so this is a good option. One thing that has occurred to me is that in front of the wheel wells there is space that seems to be totally ignored in truck campers. I wonder if anyone has ever created a little door on either side to be able to access and store items (like extra water or fuel since the area would still be fairly exposed)? It would definitely need to be reinforced and supported very well, but when space is at a premium, a little extra room there could be useful.

[@GeorgiaAstronomy]

@@CarolinaCarolina-ph9mx Thank you for watching! I'll try to answer as much as I can but feel free to reach out to me on email. [e-mail] At 10:40 time mark, The strips were fiberglass reinforcement tape. It comes in 6 and 10" wide rolls. I used it to reinforce the joints anywhere that had two panels adjoining. 1708, you will not find at the big box stores, especially in the volumes you will need. There are several stores that carry it and can be ordered on line. fiberglasswarehouse.com is one supplier I have used. The box bottom and sides, along with the wall sides on left and right sides had the 5mm plywood on them. all edges that met with a 90 degree angle, whether plywood edges or where the walls and panels met, were sanded to 45 degree angles. Reason being is that fiberglass does not form well around sharp edges. It needs to be a more gradual transition. I did wear protective equipment as you do not want the fiberglass in your lungs and eyes. At 13:41, that strip is a piece of extra foam cut at a 45 degree angle and glued into place. Again, to ease the angle from 90 to 45 degrees. The wood panels and joints were mostly glued down using epoxy resin. Some joints were also used Gorilla glue HD ultimate, from Home Depot. I bought them by the case.

[@CarolinaCarolina-ph9mx]

@@GeorgiaAstronomy Thank you so much for your response and help. I really appreciate it. 😊 There is a lot to learn with this type of building, yet at the same time, it seems more doable than a wood framed build. Plus warmer and lighter. I've made it up to Episode 11, I believe, and really appreciate the content you shared. I was bummed that the roof wasn't filmed, however, because I was really looking forward to that section. Might have even brought out the popcorn to watch that come together. 😆 This Foamie way of building is inspiring, and I I have a few ideas on things I might want to make. I need to find a good Foamie group to broaden my knowledge base so if/when I decide to build something, I will be prepared. Thank you again for your very helpful reply. 😊

[@scottkelly2200]

How many sheets of foam did you use?

[@GeorgiaAstronomy]

10 sheets

[@bradleysmith3963]

I figured the resin for the fiberglass cloth would have melted the styrofoam

[@douglasashby4349]

Epoxy resin has no styrene solvent in it. Polyester resin has styrene in it which dissolves or melts the polystyrene foam

[@jwiereng]

2:31 Are you sure it is 250 PSI compressive strength? I think it is 25 psi

[@GeorgiaAstronomy]

Dammit! You are correct. Apologies. My editor was off this day. Well actually everyday. :0

[@jwiereng]

@@GeorgiaAstronomy wouldn't it be great if we could buy actual 250 psi foam at Lowes/Rona/HomeDepot?

[@GeorgiaAstronomy]

@@jwiereng I'd be building a whole lot more stuff!!

[@douglasashby4349]

PVC foam at medium weight is close to 230PSI compressive strength. It's a lot more expensive than Polystyrene foam but you can buy it in sheets from most fibreglass speciality suppliers.

[@patrickday4206]

Have you heard of foam fusion glue watched a review was very strong

[@GeorgiaAstronomy]

@patrickday4206 I haven't heard of it but sounds right up my alley!

[@jefferyfowler5080]

I like your build. The biggest issue I have in my head is: How strong is it for lifting the whole unit with camper jacks?

[@GeorgiaAstronomy]

@jefferyfowler The weight was no issue. The choice in jacks....slightly. However, no stress cracks!

[@SuperJellicoe]

To begin with; What is in the camper when you are jacking it? In reality, the materials will support itself and a reasonable amount of materials - Clothes, cook stove and chilly box. 1000 lbs of game meat and assorted tools? Unload first. First tip it to take roadside weigh scale readings at the start of the trip and before unloading. Always interesting to realize the accumulations.

[@ArielsSky]

What is the tool called for cutting the styrofoam please

[@GeorgiaAstronomy]

Hi Ariel. Hot Wire Styrofoam cutter. www.amazon.com/gp/product/B076GX3268?ie=UTF8&psc=1&linkCode=ll1&tag=roswellastron-20&linkId=c2f560990dfd871e41b01380e7dfe6c5&language=en_US&ref_=as_li_ss_tl

[@ArielsSky]

@@GeorgiaAstronomy Thank you!

[@melyssabailey8935]

it's a soldering iron with specialized tips for cutting foam. You could probably cob one together at home if you wanted to.

[@DonaldBurgess-n9s]

how much did it weight ??

[@King_TuTT]

how strong is that thing??

[@siamaksadeghi1034]

Hello what is the program name u pattern?

[@GeorgiaAstronomy]

sketchup.com

[@DesmoProfundis]

You went from Total Boat to West System because ... hardening vagueness and something about the smell, but ... no, I don't get the idea. I'm here on KZbin to learn from other's knowledge because I haven't used epoxy with foam. It's frustrating when folks do a how to video and then act like the viewer already knows. That said, much of this video is great info and I do appreciate it. Just please don't act like "we get the idea" if you don't clearly explain what idea we should get.

[@GeorgiaAstronomy]

@DesmoProfundis I was switching between the two because the Total Boat was a 'fast hardener' (dries super quick) which is directly affected by ambient heat. The West Systems was a slow hardener. Longer working times in higher ambients.

[@Brian-os9qj]

Okay I’m interested

[@GeorgiaAstronomy]

Lost more to come!

[@justinlyle7831]

The access cab has nothing to do with the length of the bed. It has to do with the suicide doors to access the cab.

[@GeorgiaAstronomy]

@justinlyle7831 The access cab allows the bed to 6.5' while the crew cab only allows 5' bed length. The gen 1 Tundra's had the suicide doors while the gen 2's have regular opening doors.

[@justinlyle7831]

​@@GeorgiaAstronomyThe truck you're working with is a double cab which also has the option for the 8'1" bed. Not that it matters much. Just not sure why you were talking access cab. Not that it matters. LOL have a good day

[@GeorgiaAstronomy]

@@justinlyle7831 I actually just learned about the 8' bed when I was at the dealership couple of months ago. They had 1 on the lot. It certainly looked weird!

[@gerlandkent6377]

👍

[@yearofthegarden]

The full of self attitude is fragrant

[@robs4517]

Have you thought about buying an actual truck? Not a Toyota blundra? Then you can build with wood and your truck will be able to haul it.

[@timhill3330]

1 sheet of that foam board is $55