Midwestdrifter
Engineer In Residence
Greetings,
I am currently in the early stages of building out a 140” T1N. Since my design is dependent on the left-right oriented bed (I am 6’ 1”) I am starting with a custom made window flare.
Flare Space http://www.flarespace.com/ offers window flares, but for NCV3 body styles only. I have not seen anyone attempt to make of these from scratch… So here goes!
The sprinter is approximately 73 inches window to window (at the lowest point). In order to have room for insulation and about 74inches of sleeping room, the flare will need to be at least 4 inches deep. The final dimensions I decided on are 48” wide by 22.75” high by 4.5” deep.
I thought through several fabrication methods and decided to attempt a one-off fiberglass part. This method seemed best given the curvature of the sprinters window openings.
I am essentially creating a plug on the side of the van, and then doing the layup in place.
My plan is as follows.
1. Build up plug out of polyurethane foam (pink stuff from Home Depot)
2. Remove foam to create desired shape.
3. Coat plug with drywall compound, sand smooth, paint for mold release.
4. Layup fiberglass on plug and van skin.
5. Remove part from plug/van trim edges and finish as necessary.
To date I have finished the foam base and started apply the drywall compound. I have ordered a selection of fiberglass materials; several kinds of fabric and chopped mat, as well as some polyester resin. I have limited experience with fiberglass, so any advice is welcome!
I am currently in the early stages of building out a 140” T1N. Since my design is dependent on the left-right oriented bed (I am 6’ 1”) I am starting with a custom made window flare.
Flare Space http://www.flarespace.com/ offers window flares, but for NCV3 body styles only. I have not seen anyone attempt to make of these from scratch… So here goes!
The sprinter is approximately 73 inches window to window (at the lowest point). In order to have room for insulation and about 74inches of sleeping room, the flare will need to be at least 4 inches deep. The final dimensions I decided on are 48” wide by 22.75” high by 4.5” deep.
I thought through several fabrication methods and decided to attempt a one-off fiberglass part. This method seemed best given the curvature of the sprinters window openings.
I am essentially creating a plug on the side of the van, and then doing the layup in place.
My plan is as follows.
1. Build up plug out of polyurethane foam (pink stuff from Home Depot)
2. Remove foam to create desired shape.
3. Coat plug with drywall compound, sand smooth, paint for mold release.
4. Layup fiberglass on plug and van skin.
5. Remove part from plug/van trim edges and finish as necessary.
To date I have finished the foam base and started apply the drywall compound. I have ordered a selection of fiberglass materials; several kinds of fabric and chopped mat, as well as some polyester resin. I have limited experience with fiberglass, so any advice is welcome!
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