Filling void in van roof!


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firth90
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Hi,

What is the easiest way to fill the channels in the roof of my campervan (before adding a solar panel).  The attached picture shows the size of the channels.  Could I just make a lightweight filler with glass bubbles and fill the entire void?

My assumption is that the roof is GRP sprayed with car spray.  There is a fair amount of flex/twist as the roof goes up and down, although I'd say that is fairly minimal along the ridges themselves.

Many thanks
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Firth Van Roof.pdf (153 views, 741.00 KB)
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firth90
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Warren (Staff) - 9/19/2019 2:43:08 PM
You could certainly use a lightweight filler made of glass bubbles and resin.  However that would be a waste and be quite heavy.  A lighter option would be to carve some polystyrene or PU foam to shape to fill the void then bond it in place and skim over the top with the lightweight filler to give strength and seal it in.  Then once dry, paint the panel before fitting the solar panels.

Thanks Warren.  I wondered about doing that.  Would I need any glass cloth to cover the foam or would the filler be sufficient?  What thickness of filler should I be aiming for over the foam?

Thanks

GO

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