Build - Floor, Walls and Roof

We decided to get our panels locally from Creative Composites and our dealings with Paul Delacorn was great.

We did some preps on the subframe before installing the floor. It is one piece, 39mm thick made from 1.5mm fibreglass, 30mm CFR and 7mm ply. We put a coat of polyurethane on the ply to help protect it during the build. Recommendations state that the ideal minimum gap for the glue is 1mm so we pre glued some packers onto the frame. Then we sanded the frame and the floor (only where the joists came in contact with the floor). Cleaned it all down with methylated spirits (as recommended by glue supplier Fixtech 190 bought with our panels). We then got some help to lift it into place. The floor was then clamped and screwed down.

The next day Mark cut out the stairwell and installed the steps.

We then cut the Gerflor (Gravel Beige) vinyl to size, about 1mm smaller than the floor to be able to put a bead of silicon around the edge.

Preparations to the roof needed to be done before installation. There are 2 pultrusions inserted in the panel by Creative Composites to be able run 240v for the air conditioner and 12v wires to the roof vents, in addition to providing strengthening to the roof for the weight of these plus 4 solar panels.

Cutting out the openings

Pealing back the plastic and cleaning with methylated spirits.

Gluing it down with Fixtech 190

Installing internal clips

Dometic Midi Heki fitted.

Gluing in the Fantastic roof vent

Screwing down the Fantastic

We measured up all the panels and the floor and needed to trim 3mm off the length of all the panels due to the subframe measurements. These panels are 28.6mm thick (2mm external fibre glass, 25mm CFR and 1.6mm internal fibre glass).Then applied the fixtech 190 glue to the subframe and the edges of the floor panel and then along the rebated edges. Mark screwed some timber on the corners level with the bottom of the subframe to sit the panels on. We clamped and taped the edges for a few days.

We began with the passenger side.

Then the front panel. Putting the Fixtech on the panel due to not being able to reach frame because of the cab.

Then the drivers side panel was put in place.

Next the roof was walked in through the back and lifted into position, placing it in the rebates of the walls.

Last was the back panel. Job well done.