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04-03-2014, 03:52 PM
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#21
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Commercial Member
Trailer: 1988 Scamp 13 ft and 1982 Perris Pacer 13 ft
Posts: 822
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More body work, then a coat of primer, then more body work...
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04-04-2014, 05:07 AM
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#22
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Moderator
Trailer: 2009 19 ft Escape / 2009 Honda Pilot
Posts: 6,283
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Looking slick.
__________________
2017 Escape 5.0 TA
2015 Ford F150 Lariat 3.5L EcoBoost
2009 Escape 19 (previous)
“Most folks are about as happy as they make up their minds to be.” — Abraham Lincoln
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04-04-2014, 06:37 AM
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#23
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Senior Member
Name: jim
Trailer: 2022 Escape19 pulled by 2014 Dodge Ram Hemi Sport
Pennsylvania
Posts: 6,710
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What is your estimate of the weight of the mold we are seeing take shape?
__________________
Jim
Never in doubt, often wrong
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04-05-2014, 08:13 PM
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#24
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Commercial Member
Trailer: 1988 Scamp 13 ft and 1982 Perris Pacer 13 ft
Posts: 822
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Weight of the mold? No clue... Why do you ask?
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04-06-2014, 06:30 AM
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#25
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Senior Member
Name: jim
Trailer: 2022 Escape19 pulled by 2014 Dodge Ram Hemi Sport
Pennsylvania
Posts: 6,710
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Just curious as to ease of movement and actually upon second thought, I was more interested in the weight of the composite shell coming out of the mold.
__________________
Jim
Never in doubt, often wrong
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04-06-2014, 07:01 AM
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#26
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Senior Member
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Surely what Robert is posting photos of is the 'plug' - the single-use male shape from which the female production 'mold' is taken, with (male) production parts being molded inside the mold.
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04-06-2014, 07:54 AM
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#27
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Commercial Member
Name: Ian
Trailer: 1974 Boler 1300 - 2014 Escape 19'
Alberta
Posts: 1,380
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Great progress Robert. This helps everyone appreciate the amount of work that goes into just the shell ... not to mention all the other components.
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04-06-2014, 08:32 AM
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#28
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Senior Member
Trailer: 1984 Perris Pacer ('Tillie')
Posts: 157
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Love how it's coming along, Robert!
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04-06-2014, 06:28 PM
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#29
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Commercial Member
Trailer: 1988 Scamp 13 ft and 1982 Perris Pacer 13 ft
Posts: 822
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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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04-06-2014, 06:31 PM
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#30
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Senior Member
Name: Carl
Trailer: 2013 Lil Snoozy #161 (SOLD)/2010 Tacoma
NE Oklahoma
Posts: 2,358
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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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05-04-2014, 11:54 AM
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#31
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Commercial Member
Trailer: 1988 Scamp 13 ft and 1982 Perris Pacer 13 ft
Posts: 822
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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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05-04-2014, 12:01 PM
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#32
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Commercial Member
Trailer: 1988 Scamp 13 ft and 1982 Perris Pacer 13 ft
Posts: 822
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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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05-04-2014, 12:13 PM
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#33
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Senior Member
Name: Philip
Trailer: Escape 13 /Hyundai Santa Fe
British Columbia
Posts: 471
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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.
__________________
It's not the size.....
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05-04-2014, 12:14 PM
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#34
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Senior Member
Name: jim
Trailer: 2022 Escape19 pulled by 2014 Dodge Ram Hemi Sport
Pennsylvania
Posts: 6,710
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Amazing…..
__________________
Jim
Never in doubt, often wrong
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05-04-2014, 12:21 PM
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#35
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Commercial Member
Trailer: 1988 Scamp 13 ft and 1982 Perris Pacer 13 ft
Posts: 822
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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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05-18-2014, 09:03 PM
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#36
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Senior Member
Name: Dale
Trailer: 2010 EggCamper; 2002 Highlander 3.0L; 2017 Escape 21'; 2016 F-150 5.0L Fx4
Colorado
Posts: 748
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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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05-20-2014, 07:02 PM
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#37
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Commercial Member
Trailer: 17 ft Casita Spirit Deluxe
Posts: 490
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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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05-22-2014, 06:32 PM
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#38
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Senior Member
Name: Francesca Knowles
Trailer: '78 Trillium 4500
Jefferson County, Washington State, U.S.A.
Posts: 4,670
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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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05-22-2014, 09:03 PM
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#39
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Moderator
Trailer: 2009 19 ft Escape / 2009 Honda Pilot
Posts: 6,283
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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'.
__________________
2017 Escape 5.0 TA
2015 Ford F150 Lariat 3.5L EcoBoost
2009 Escape 19 (previous)
“Most folks are about as happy as they make up their minds to be.” — Abraham Lincoln
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09-04-2014, 10:31 PM
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#40
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Senior Member
Name: Dale
Trailer: 2010 EggCamper; 2002 Highlander 3.0L; 2017 Escape 21'; 2016 F-150 5.0L Fx4
Colorado
Posts: 748
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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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