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Timber Wolf 09-13-2014 02:00 PM

Yes, please keep posting progress. It is very interesting seeing modern egg construction. I really like your layout too.

Nelmes 09-15-2014 12:55 PM

Amazing Post!! Looking forward to reading more!!

Ken C 09-23-2014 09:41 AM

3 more pics posted

David Tilston 09-23-2014 10:58 AM

Is it just me, or do the first five pictures look like a scale model?

Jim Bennett 09-23-2014 11:46 AM

Either that, or they have a drill bit the size of a power pole. ;)

Robert Johans 09-23-2014 01:24 PM

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.

Robert Johans 09-23-2014 01:33 PM

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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.

Robert Johans 09-23-2014 01:37 PM

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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.

Robert Johans 09-23-2014 01:53 PM

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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.

Ken C 09-23-2014 02:14 PM

Your new avatar reminded me of battlestar for some reason :D

Robert Johans 09-23-2014 02:43 PM

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Funny, we too often make reference to the "Cylon" shape of the front wind screen. But actually, the design is more influenced by the shape of modern ski goggles.

Green Frog 09-23-2014 03:01 PM

I'm coming to this thread really late, but boy howdy am I ever impressed! I especially like the idea of a complete "tub" for the bottom and having a unit-body type frame arrangement. I think this is going to be a real winner. I'm wondering though, why use wood cabinetry rather than the inner layer fiberglass units like the old Burro? It seems like that would increase shell strength while saving weight. Regardless, it looks like a great project and further, it appears you are making every effort to do it all as well as it can possibly be done.

Best Wishes,

Mike Magee 09-23-2014 06:06 PM

Some of us like the look of wood. That might be one reason, but only the builder knows for sure.

Jim Bennett 09-23-2014 06:18 PM

While I understand some of the benefits of an inner shell, I MUCH prefer the look of real wood. Trailers like the Oliver with its white interior look very institutional, kinda like a hospital, to me. Maybe if it was coloured right like some trailers, but still, wood is my first choice too.

David B. 09-23-2014 06:54 PM


Originally Posted by Jim Bennett (Post 484220)
While I understand some of the benefits of an inner shell, I MUCH prefer the look of real wood. Trailers like the Oliver with its white interior look very institutional, kinda like a hospital, to me. Maybe if it was coloured right like some trailers, but still, wood is my first choice too.

One could have the best of both worlds (lightness & durability of fiberglass) with this 3M product.

honda03842 09-23-2014 07:15 PM

This company makes all kinds of vinyl, some specifically for curved surfaces.

Graphic Products - Graphic Products

Steve Outlaw 09-23-2014 07:58 PM

We have an Oliver (our second one actually) and we love the white interior. As far as it looking " a hospital" I'm unclear on where that notion has come from. I've worked in the largest hospital in rural America for the last 40 years and I can't think of a single white wall in all of its several million square feet. Don't misunderstand, I love wood. Our home has a custom built oak library and it's beautiful (I know, I built it.) The problem I have with the "wood" in most of our trailers is that it is not cabinet grade hardwood rather being, at best, nice Veneered Plywood going downhill toward MDF or vinyl covered whatever. I agree that a colored gel-coat on the interior would be nice but not very feasible from a production standpoint. Besides, the white gel-coat is the most versatile as a basis for any color palate.

Robert Johans 09-23-2014 10:16 PM

Our intention is to create a modern, "mid-century" design aesthetic with the interior. In fact, our furniture has been inspired by that of some pieces designed by Charles and Ray Eames. Because the space is relatively compact, the cabinetry must feature clean lines, simple forms, and light tones.

I don't agree that fiberglass furniture is necessarily lighter than wood. In our case, much depends upon construction methodology and material choices. However, you won't ever find MDF, particleboard, or any other "fake" wood used anywhere on the Nest.

Sent from my iPad using Fiberglass RV

Robert Johans 09-25-2014 01:13 PM

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More tooling updates!

The bottom shell form has now been separated from the mold. The mold is completely framed within its rotisserie armature. As per the top shell mold, this gets QC'd for surface imperfections and then buffed out.

Robert Johans 09-25-2014 01:16 PM

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The top shell mold has been completely buffed out now and is ready to produce actual parts.

Our first "pull" occurs next Wednesday!

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