Nest Caravans — Building a new FG trailer, step by step - Page 3 - Fiberglass RV


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Old 04-06-2014, 07:28 PM   #29
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Thanks all for your comments.

Yes, these photos show the development of the "plug" for the top shell. Obviously, the plug must be perfect to build a perfect mold from which to pull perfect parts.

As the finishing for top shell plug gets dialed in, the bottom shell plug form is being cut and assembled, and the "rear cap" works its way through final engineering.

The process is arduous, but I am confident that we'll have a beautiful product when finally finished.
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Old 04-06-2014, 07:31 PM   #30
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I appreciate it isn't a "government job."
And "good enough" isn't good enough.

As you say, a perfect mold takes a perfect plug.
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Old 05-04-2014, 12:54 PM   #31
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Hi Folks, been about a month since my last post. Here's an update on the progress of our Nest:

The fine details of the upper shell "plug" are being dialed in. The foam for the lower shell plug has been cut, assembled, and encased in fiberglass. (Photos below show bottom form upside down.) The "rear cap" has completed engineering and files are on the way to the CNC machine.

Again, the process has been excruciatingly slow. I am no longer making predictions about the delivery of the first prototype! Gotta stay patient, take our time and ensure perfect results.
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Old 05-04-2014, 01:01 PM   #32
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More photos...

After the foam is cut and assembled, it is encased in a coat of fiberglass and resin. Then automotive body filler is worked onto the form and shaped. When this is near perfect, the form will get a coat of primer and reworked as necessary.
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Old 05-04-2014, 01:13 PM   #33
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fascinating Robert. Thanks for sharing that. From your avatar it looks like it may be the "Airstream" of the FG world. Wishing you best.
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Old 05-04-2014, 01:14 PM   #34
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Amazing…..
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Old 05-04-2014, 01:21 PM   #35
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Meanwhile, the interior furniture components have been designed and translated to CNC files for the cabinet maker. Yes, real wood, high-end cabinetry...

The left side of the Nest will feature the the sink and shower enclosure; the right side has the cooktop, refrigerator, and countertop. The front end contains the queen-size mattress, with access to storage in front and below.
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Old 05-18-2014, 10:03 PM   #36
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Looking great! Please keep the photos coming! I appreciate that you're taking your time to do it right, but I sure hope you can get a prototype to some rallies this Summer. I'm sure it will draw a huge crowd wherever it goes. I can't wait to step inside one and "try it on for size"!
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Old 05-20-2014, 08:02 PM   #37
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Fascinating stuff Robert!
Thanks for allowing us to watch the process from the very beginning.
I too can't wait to see one in person.
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Old 05-22-2014, 07:32 PM   #38
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Will you wait until both bottom and top half plugs are finished before proceeding to making the molds and casting the first actual body?

Also, I know you asked us all to limit discussion in this thread to the making of the plugs, but I hope if you don't go on to post the next processes here you do so in another thread. I'm really hoping to watch this from start to finish...
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Old 05-22-2014, 10:03 PM   #39
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Francesca, my purpose for starting this thread (as per your request), was so we could watch and drool over the whole process, and that any discussion over the merits of components and other decisions made, be done elsewhere.

The thread title, Nest Caravans — Building a new FG trailer, step by step, kinda tells it better than my blurb at the beginning.

I too am enjoying the photos shared by Robert. Let's keep 'em comin'.
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Old 09-04-2014, 11:31 PM   #40
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Robert, It's been four months since we've heard from you. Summer has come and almost gone. What's happening with the Nest? Any production models on the road yet? Any photos of actual camped-in-the-boonies Nest caravans we can analyze, scrutinize, drool over and dream about? Dale
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Old 09-05-2014, 05:41 PM   #41
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Hello everybody!

Yep, it's been a while since my last post, but that does not mean we haven't been working everyday to bring Nest to reality.

Fact is, we had some unforeseen production problems with our plugs that put us way behind, but those issues have been resolved and we are now making some real progress.

Because of the several automotive styling details inherent to our design, ironically, a tremendous amount of hand work is required to give the plugs a "machined" look. All of the lines need to be absolutely clean, true and consistent.

Here is a look at the top shell plug as it nears finishing form before the mold is built around it.
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Old 09-05-2014, 05:53 PM   #42
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The lower shell is also nearing completion. It is now in the middle of final primer coats and "blocking" — where the surface is repeatedly re-sanded with ever decreasing grits of paper.

These shots show the shell upside down, giving you a good view of the "frameless" design. You'll see channels upfront that provide anchoring points for our towing "delta." The torsion axle, of course, spans between the wheel wells, and is mounted via custom brackets through the shell body. (Unlike most other FG trailers, ours features a floor nearly 2" thick built up with a variety of composite materials, including structural foam and "hard" panels for the attachment points.)

The close-up shot of a wheel well shows the various engineered surface "joggles" that accommodate the custom axle brackets, as well as the wheel flares.
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