Nest Caravans — Building a new FG trailer, step by step

[Robert Johans]

Note: This thread has been split away from the other Nest Caravan thread, in order for Robert to be able to take us through the process of building the molds for the new trailer. Please try to keep this thread on the topic of the Nest's mold-building process. Separate threads should be started for any other topics regarding Nest Caravans.

Our CNC files are finally finished and we are at last cutting forms for our pre-mold patterns — aka: "plugs".

Our fabrication shop uses a two-axis cutter to shape 4" thick pieces of foam. Here you can see how the router tool cuts the foam.

[Robert Johans]

After cutting, these many separate layers of foam are then stacked and glued together to complete the total shape.

After gluing, the total assembly is hand sanded, then measured with a scope for accuracy.

Tomorrow, a layer of fiberglass will be applied to the foam. This top coating then gets prepped and polished for the construction of the actual mold. Stay tuned for that!

[Jim Bennett]

Very cool, Robert. Do keep us informed of the progress, and you know we all just love photos.

[Francesca Knowles]

Cool! Hopin' to see the whole process, step-by-step...

[carlkeigley]

Great shots.........I'm a big fan of step by step shots.
The naked truth and all that.........

[WildBirder]

Wow, very interesting. Thanks for letting us in on the process. :

[Francesca Knowles]

Feelin' like an onlooker at a birth; thanks for letting us into the delivery room, Robert!

[Robert Johans]

As mentioned above, the foam form gets covered with fiberglass. Today three layers of FG cloth will be cut to shape and draped over the form. Tomorrow, resin is to be applied to the cloth, followed by shaping and polishing.

[carlkeigley]

Originally Posted by Francesca Knowles

Feelin' like an onlooker at a birth; thanks for letting us into the delivery room, Robert!

That's a great way of putting it.
Just like watching a colt or calf or even a human baby.

Love to watch the birth of any brand trailer.

[Jim Bennett]

Originally Posted by Francesca Knowles

Feelin' like an onlooker at a birth; thanks for letting us into the delivery room, Robert!

And we all get to be godparents.

[carlkeigley]

Originally Posted by Jim Bennett

And we all get to be godparents.

Jim, that's the emotion.................thanks.

Godparents.......ain't we lucky.

[Jim Bennett]

Originally Posted by Robert Johans

As mentioned above, the foam form gets covered with fiberglass. Today three layers of FG cloth will be cut to shape and draped over the form. Tomorrow, resin is to be applied to the cloth, followed by shaping and polishing.

I see lots of squeegeeing in your future.
It reminds me of glassing my cedar strip canoe, just on a WAY larger scale.

[Robert Johans]

All hands on deck as the resin is applied to the fiberglass fabric. Even the fabrication company's president pulled on gloves and a respirator to help.

[Robert Johans]

After the resin sets, the crew goes to work smoothing out the body. Gaps and cracks are filled with Bondo. Then everything is re-sanded. When this is completed a few coats of primer are applied, then more sanding.

All this work to make the plug/pattern perfect for the actual mold...

[kdhanso]

Robert, This is so much fun to see. Thanks for sharing the details.

[brian m.]

Yes, very exciting! Can't wait to see one in person someday.

[Robert Johans]

More hand work to clean up the form before the primer goes down.

Can you get a sense of some of the body lines yet?

[Jim Bennett]

Looking good. Does the prime coat reveal any additional imperfections that need to be faired out before you make the mould?

[Andrew Gibbens]

Robert, should you not put an advisory note in the thread title - "Beware, contains images of hand sanding"?

Amateurs normally assume that power tools must be used for everything, so they need to be protected from this assault on their senses and beliefs.

My thoughts are with your fairing guys and their finger ends....

[CindyL]

Very interesting. Like 3D printing with the layers.

CindyL