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downforce
downforce
posted 13 Years Ago
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Hi
I am an absolute rank amateur with no previous experience other than a few GF/GRP Moulds at school (a long time ago).
In Order to keep my question simple I wont go into the detail of what I am trying to do but the closest thing I can suggest is if I wanted to build a CF caravan (yes the thing you tow) and I get that I can buy some flat sheets of sandwich and stick them together and end up with a very square caravan but I am thinking a bit more adventurously than that.
So here goes... I would like to build a caravan and I assume (but ask the question anyway) is it practical to build a BIG box using vacuum induction forming techniques or do I have to create it in sections and I have a fairly good understanding of bonding and area vs. strength and concepts like tensile strength and stressed members, but what I don't get is where I start. For example do I plan to build a nose-cone and tail then fill the middle in with square flat sheets?
If I go down that route how do i get the right strength / cost ratio and on a practical note - how do I fit doors and windows?
I also assume I'd need a big thick sandwich construction floor and am thinking about honeycomb but I don't seem to be able to find anything that tells me how to construct a section of rigid panel using the honeycomb.
Any thoughts?
PS I appreciate this size/scale isn't something a beginner should be having a go at, but it's the only thing I'm interested in building at the moment!
PPS - just watched the video of the indian guys building a 42ft boat in one go so it must be do-able if very complicated!
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Matthieu Libeert
Matthieu Libeert
posted 13 Years Ago
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I will leave the advice to real pro's over here
but the first thing I think of, It will be a very expensive caravan if you do it in carbon fiber and quit a difficult project
Matthieu Libeert
Founder MAT2 Composites X Sports
website:
www.mat2composites.com
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Joe
Joe
posted 13 Years Ago
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Hi.
Ok, I dont know anything about caravans, but doesn't it need some structure to maintain it?
I mean, a structure (not only the chassis itself) on which panels are set (screws, glue, rivets, whatever) ?
Then if its the case, I would build an aluminium structure on which I set my panels.
But okay it depends the size, shape etc. Maybe a few pics of what you want would help us giving the best advices we can.
Must be waaayy cool to stare at carbon fiber when in the bed... no wonder you would have sweet dreams
A $1000 electronic device will always protect a 10 cents fuse
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downforce
downforce
posted 13 Years Ago
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Well I have seen a carbon-fibre monocoque (?) vehicle frame that didn't have any (metal) frame.
So I guess it depends on the thickness/layup of the body.
As I mentioned I did also consider using honeycomb core for stiffness - I guess that would be strong enough to not need a frame ?
DF
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Ballistical
Ballistical
posted 13 Years Ago
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I am also no pro on the composites stuff but have done similar(ish) projects in the past.
I would have thought that you're most difficult hurdle to overcome would be getting the thing road legal and would suggest that you would firstly want to find out from the DVLA etc. what standards exist for caravans as I would assume that its going to need to be tested once complete, for its road-worthiness.
If it were me, I would definitely look into getting a donor caravan for your chassis, wheels etc. and then build the carbon fibre around the existing chassis. To start from scratch would be far more expensive and difficult.
I do agree though, that you could probably get the required stiffness from a monocoque structure without the need for an internal frame.
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