Nest Caravans Building a new FG trailer, step by step - Page 10 - Fiberglass RV


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Old 10-03-2014, 05:31 PM   #127
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Having learned much from the experience with the top, the infusion process went even more smoothly on the lower shell.
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Old 10-03-2014, 05:52 PM   #128
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Admittedly, these first units are not perfect. We learned a lot about the process and discovered some errors along the way.

With the parts now out of the molds we can see some problem areas within the molds themselves that need correcting. Some fine-tuning will be necessary before I am completely satisfied with the results.

Nevertheless, the shells look awesome. I am extremely pleased with the decisions we've made so far towards delivering an outstanding product.

These shells will be moved back into the fabricator's shop for edge trimming, sanding of some rough spots inside, and then a thorough, thorough inspection. We'll build and attach the front towing delta, as well as mount the axle/wheel/tire assembly to the lower shell.

Concurrently, the rear cap, door, wheel flares, and nosecone will be infused. With luck we should have all major FG parts made by the end of next week. Then comes assembly of the complete body.

Stay tuned.
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Old 10-03-2014, 09:59 PM   #129
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Absolutely beautiful! Congratulations!
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Old 10-03-2014, 10:57 PM   #130
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CONGRATULATIONS Robert, Your write-up is excellent and your trailer is looking awesome,
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Old 10-04-2014, 07:49 AM   #131
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Oh WOW. Impressive!
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Old 10-04-2014, 10:16 AM   #132
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Quote:
Originally Posted by Robert Johans View Post
Nest will instead feature the design-award winning Thetford "Curve" porta-potty, and a gray water external tote.
That's the same decision I made for my Compact Jr. rebuild!
I'm using a Barker Low Silhouette "Tent Camper" Tote. I'm making a cradle just forward of my axle for it to ride under the floor, as if it were a regular holding tank. To me it's the best of both worlds.
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Old 10-04-2014, 10:25 AM   #133
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This is why I love fiberglass. Is there any question, now, about why things cost what they do?..This is first rate
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Old 10-04-2014, 11:46 AM   #134
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Wow - what a lot of work! But it looks great!
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Old 10-04-2014, 02:25 PM   #135
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As you can see, infusion is a very laborious and expensive process. As it pencils now, easily two-thirds of our production costs lie just within the manufacture of our shell bodies and FG components. Perhaps this is why no other American FG trailer builder has yet embraced infusion technology.

As mentioned earlier, the ratio of FG to resin within traditional chopper gun production is about 35% FG to 65% resin. This not only adds brittleness to the product, but nearly doubles its weight, as compared to the infusion process. Toss into the resin (as is often done as a cost-cutting measure) talc or some other inert medium, and the overall strength is further diminished. And, when considering environmental and health-safety issues, the airborne chopper gun option is at minimum, dubious.

Our fabricator estimates the weight of an infused Nest shell mounted to our axle/wheel/tire assembly and front towing delta to be less than 900lbs. Even if we add another 1000lbs. to the interior, Nest could very well be the lightest 17' travel trailer in the industry. Less weight, better fuel economy any mid-size SUV, cross-over or light-duty truck can pull one.

Except for cost, old school chopper gun methodology simply pales when compared to the many benefits produced by modern infusion technology. And we at Nest are committed to producing a compact travel trailer of the highest quality. We're keeping our fingers crossed that some segment of the marketplace will also buy into that philosophy.
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Old 10-04-2014, 03:02 PM   #136
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I think snoozy does Vacuum Infusion technique
Lil'Snoozy owners : please contact me

"This camper was built using a vacuum bag infusing process, this process
removes all air from the fiberglass before resin is introduced. Your
camper and all that follow will be built using what is called a "counter
mold" or Light RTM process. This uses what is essentially a second mold in
place of the bag. The "counter mold" will give us the same gloss and
texture as the exterior with the same color (a light tan color). It is an
in depth process that I will explain more completely if you are interested."

Lil Snoozy vs Scamp discussion (split from Classifieds)
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Old 10-04-2014, 03:12 PM   #137
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Quote:
Originally Posted by Robert Johans View Post

As mentioned earlier, the ratio of FG to resin within traditional chopper gun production is about 35% FG to 65% resin. This not only adds brittleness to the product, but nearly doubles its weight, as compared to the infusion process. Toss into the resin (as is often done as a cost-cutting measure) talc or some other inert medium, and the overall strength is further diminished. And, when considering environmental and health-safety issues, the airborne chopper gun option is at minimum, dubious.

Our fabricator estimates the weight of an infused Nest shell — mounted to our axle/wheel/tire assembly and front towing delta — to be less than 900lbs. Even if we add another 1000lbs. to the interior, Nest could very well be the lightest 17' travel trailer in the industry. Less weight, better fuel economy — any mid-size SUV, cross-over or light-duty truck can pull one.
Robert,
I absolutely love the thread but wondered about the above statement.

This sort of Suggests that the empty shell of a Scamp 16 weighs 1800 pounds on it's frame. Is this true?
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Old 10-04-2014, 03:33 PM   #138
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I believe the empy Snoozy shell on its frame and axle is about 1200 lb IIRC; if so, you've knocked off about 25% of that weight. I think the added shell strength and reduced brittleness will be a more important factor, though.
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Old 10-04-2014, 03:35 PM   #139
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Nope, not saying that, Norm. But, when comparing two equally sized forms (L x W x D), chopper gun produces a unit that is twice as heavy as the infused. Or so I am told by the materials rep. I have no idea what the Scamp shells weigh. I would be curious to learn, though.


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Old 10-04-2014, 04:15 PM   #140
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Thank you, Ken, for alerting/correcting me as to LilSnoozy's infusion manufacturing techniques. (Also, thanks for that link.) Apologies for the mistake. Looks like they should get full credit for leading the way in our industry. Congrats!

Mike, not sure if we can fairly compare the weight of Lil Snoozy to the Nest. I believe the total dimensional area of our shell (including the nosecone storage box) is greater than theirs. We are also featuring larger wheels, tires and brake hubs. But honestly, we won't really know the weight of a Nest until it is completely built and accurately weighed. Hopefully, I won't have to return to this forum, hat in hand, begging forgiveness for understating the numbers on the scale!
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