Nest Caravans — Building a new FG trailer, step by step - Page 5 - Fiberglass RV


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Old 09-12-2014, 12:04 PM   #57
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Quote:
Originally Posted by David Tilston View Post
just out of curiosity, does the plug survive the creation of the mold?
In the work I've done in this field, it does. (Hand layup carbon fiber.)
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Old 09-12-2014, 11:15 PM   #58
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Quote:
Originally Posted by David Tilston View Post
just out of curiosity, does the plug survive the creation of the mold?

Yes it does. In fact, we'll keep it stored and secured in case we need to build another mold someday.


Sent from my iPad using Fiberglass RV
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Old 09-12-2014, 11:26 PM   #59
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I was worried the plug would not strip out of the mold due to the recessed sides! Now I can rest easy. Looking good!
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Old 09-13-2014, 10:31 AM   #60
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We were very careful to ensure that there would be no negative "draft" issues with this design.

Though the window chamfers imply a possible sticking point, the geometry of the shell form actually mitigates any problems with those angles.

That said, there were some concerns about removing the plug from the mold due to its sheer size and associated surface tension, et al. But it slipped out with just a little coaxing — which bodes well for us when we get to removing the actual parts.

This image shows the intact plug in the foreground, with the mold in the background, suspended at 90° within its "rotisserie" armature.
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Old 09-13-2014, 03:00 PM   #61
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Yes, please keep posting progress. It is very interesting seeing modern egg construction. I really like your layout too.
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Old 09-15-2014, 01:55 PM   #62
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Amazing Post!! Looking forward to reading more!!
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Old 09-23-2014, 10:41 AM   #63
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3 more pics posted https://www.facebook.com/media/set/?...6936952&type=3
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Old 09-23-2014, 11:58 AM   #64
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Is it just me, or do the first five pictures look like a scale model?
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Old 09-23-2014, 12:46 PM   #65
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Either that, or they have a drill bit the size of a power pole.
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Old 09-23-2014, 02:24 PM   #66
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About the posted Composite Approach Facebook photos... Yes, that was an scale model of an earlier concept. The actual product has since evolved, as shown on this forum thread.
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Old 09-23-2014, 02:33 PM   #67
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Tremendous amount of handwork to ensure that the mold is absolutely true and defect-free. Obviously, any imperfections in the mold are transferred to the actual part.

The production team has been meticulous in their approach — often returning to areas already buffed out — just to resolve the slightest of inaccuracies.
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Old 09-23-2014, 02:37 PM   #68
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The lower shell plug has been finished and encapsulated to create the mold. Like the upper shell, this mold also gets a "rotisserie" frame work built around it.
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Old 09-23-2014, 02:53 PM   #69
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The Nest is comprised of three major FG parts: the upper and lower shells, and the "rear cap." As shown in the previous post, the rear cap features integrated hinging for the entry door, as well as an integrated upper "light bar" — three equally spaced red lights required to indicate a vehicle of 80" or more.

The Nest also features a front storage compartment — we're calling the "nosecone." This will hide the propane tank and provide extra space for stashing stuff best kept outside. Equally important, is the streamline aesthetic this adds to the front end.

For this plug, layers of an "MDF" type of wood product were cut to shape, stacked, and glued. Then sanded, primed and sanded again. Over and over until the finish is ready for a final polish.
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Old 09-23-2014, 03:14 PM   #70
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Your new avatar reminded me of battlestar for some reason
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