Nest Caravans — Building a new FG trailer, step by step - Page 4 - Fiberglass RV


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Old 09-05-2014, 06:01 PM   #43
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The Nest shell body consists of three main components: upper and lower shells, plus our rear "cap" which accommodates the entry door.

Here are a couple images of the foam cut by the CNC machine of the rear cap. These, obviously, get glued together and then get sprayed with primer and worked with sand paper to a finished lustre.

Also shown, is a CNC test mold that we'll prepare to use for our wheel flares.
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Old 09-05-2014, 08:05 PM   #44
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Just got a sample wheel flare pulled from the mold to lay up against our lower shell. We also placed our wheel/tire assembly into place to check for fit. We are featuring a 16" wheel in order to better match the scale of a typical modern tow vehicle.
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IMG_0515.jpg  
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Old 09-05-2014, 08:10 PM   #45
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Here's another look at the rear "cap" plug. Again, this gets primer and lots of sanding and polishing before the mold is made. (Sorry, this is upside down.) Also, a look at the entry door plug. (Right side up.)This shows the finished product, polished and ready for the mold.
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Old 09-05-2014, 08:14 PM   #46
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The top shell plug is now encapsulated by the mold. A steel armature, or in our case, a "rotisserie" will be built around the mold to facilitate the FG material lay-up and infusion process.
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Old 09-05-2014, 09:29 PM   #47
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Thanks for checking in Robert! So many of us were wondering how the NEST was coming along. Lookin' GREAT

Hot Rodders are very familiar with a "rotisserie"
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Old 09-05-2014, 09:57 PM   #48
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Looking great! Really coming along nicely! Please don't make us wait so long for the next update and photos.
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Old 09-06-2014, 12:30 AM   #49
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Great to see the progress, Robert. Looking forward to seeing it develop further.
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Old 09-06-2014, 07:35 AM   #50
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Can't wait to see the rest and finished egg.
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Old 09-06-2014, 07:49 AM   #51
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Thank you for sharing, it helps make us part of the birth.
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Old 09-11-2014, 03:54 PM   #52
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Here are a couple shots of the top shell plug, and followed by a few of the actual mold suspended within the rotisserie armature.
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Old 09-11-2014, 03:57 PM   #53
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Top shell mold...
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Old 09-11-2014, 07:31 PM   #54
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Isn't this fun! We get to see how everything comes together and those that are thinking a Nest are in their future... will ABSOLUTELY, POSITIVELY love to follow along.

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Old 09-12-2014, 09:56 AM   #55
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Robert! thanks very much for the blow by blow of the build!
Enjoying every pic
Fred
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Old 09-12-2014, 09:58 AM   #56
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just out of curiosity, does the plug survive the creation of the mold?
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