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Old 11-14-2015, 12:24 PM   #111
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The front had the heavy cardboard as I have heard most of the builders in that year did the same. Didn't want to spend time on wood going around those curves. I can also see why they put fibreglass caps on the front of the 5ers now too.
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Old 11-14-2015, 01:29 PM   #112
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Cardboard curves easier as 1/8 or 1/4 ply wood and is a lot cheaper. On mobile homes prior to 1995 they used it for the roofs too before metal went over.
Curving around wood is done with steam or a dry method is cutting grooves 1/2 " apart. Nowadays weight is the biggest concern with high fuel prices.


Yeah fiberglass caps you can prebuild and install. Problems with fiberglass is yell coat cracking I have seen that in a lot older units too (had one myself). Different materials have different structure faults.
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Old 11-14-2015, 01:33 PM   #113
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Ya I use to steam wood as I had a 1964 34 foot Chriscraft mahogany planked hull.
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Old 11-15-2015, 03:53 PM   #114
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I drilled 2 1 1/2" holes in the filon where you can see in the other pictures where I said it looked like delamination but it was just not glued. I sprayed in the glue then screwed the 2 x 6 on the face to pull it all back in. It looks good but won't know until I take the 2 x 6 off. I also reglued the top of the trailer & pulled it tight to follow the contour. It looks good as well. I put a little hood over my kerosene heater to help with the drying. Although it was 60 degrees in the shop it cant hurt.
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Old 11-18-2015, 05:52 PM   #115
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Fixed the boo boo's. Glue is setting. I had to cut a slit right across the lower underhang where the 2 x 6 is. The filon actually left a "bag" just under the overhang. I had to cut an 1/8 off one piece to pull the filon back in tight. It's hard to do the front piece. But it's done , I hope.
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Old 11-18-2015, 08:28 PM   #116
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Cardboard curves easier as 1/8 or 1/4 ply wood and is a lot cheaper. On mobile homes prior to 1995 they used it for the roofs too before metal went over.
Curving around wood is done with steam or a dry method is cutting grooves 1/2 " apart. Nowadays weight is the biggest concern with high fuel prices.


Yeah fiberglass caps you can prebuild and install. Problems with fiberglass is yell coat cracking I have seen that in a lot older units too (had one myself). Different materials have different structure faults.
Actually they make a plywood that will take curves very easy, no kerfing needed. It is called wiggle board, but is a tad more expensive than standard plywood. I used it all the time on round columns, rounded cabinet ends etc.
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Old 11-18-2015, 08:33 PM   #117
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I drilled 2 1 1/2" holes in the filon where you can see in the other pictures where I said it looked like delamination but it was just not glued. I sprayed in the glue then screwed the 2 x 6 on the face to pull it all back in. It looks good but won't know until I take the 2 x 6 off. I also reglued the top of the trailer & pulled it tight to follow the contour. It looks good as well. I put a little hood over my kerosene heater to help with the drying. Although it was 60 degrees in the shop it cant hurt.
I don't know exactly what type of plastic panel your using, but many plastics are thermoforming, which means you heat them and they will then form to that shape. Standard "Formica" is a thermoforming material. There are specific temperatures needed to form the plastic, once it is formed it will hold that shape. If you try and form it without the heat, it will always want to pull back to straight. Also contact adhesive needs pressure to bond properly. Typically a minimum of about 20 lbs per sq inch applied equally over 100% of the bond. You may want to ask if the plastic your using is thermoforming plastic. Thermoforming plastics can form to very small radius, ie Formica can form to about 3/16" radius without cracking.

Good luck, it's fun to watch your progress.
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Old 11-18-2015, 08:36 PM   #118
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It's Filon. Half fibreglass, half plastic. It's what the coach was built with.
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Old 11-18-2015, 09:15 PM   #119
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Looks like it's starting to come together. Glad you're not letting it whoop you, and glad you're making some progress. I know there are times I've dealt with things not working quite like planned, I walk away cursing the crap out of thin air, come back later and it all works out in the end. Keep it up man, keep it up.
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Old 11-18-2015, 09:17 PM   #120
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It's Filon. Half fibreglass, half plastic. It's what the coach was built with.
I Understand it is an FRP (fiberglass reinforced plastic), it may or may not be a thermoforming type plastic. I would ask the mfg.
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