Building is underway! This first video is the construction of the floor. The design will greatly improve on insulation compared to our current Lance camper. Building the floor and walls as torsion boxes will also provide a level of rigidity to compensate for the twisting truck frame without stressing the camper as we manuever off road.
Materials List
The below is a list of materials used for this portion of the construction. As the build progresses, I’ll eventually add a component cost and weight estimate.
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What’s next
The walls and roof will be coming together following the same construction methods over the next week or so. Then the box will be fully assembled. Our goal for the next video is to have the box assembled.
Working on Exploring 
Hi – very interesting construction method floor and walls….
Can you tell me why you are cutting the isolation in pieces in stead of keeping it in one piece ? Is it to have a more rigid construction or ?…it is a lot of work… the isolation is already rigid when you paste in a sandwich construction between two pieces of plywoord
Thanks for your answer
Good luck
Marc
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The insulation is rigid but not strong/stiff. The strength of the panel is created by the skins of 5mm plywood being separated by a strong member , in this case, the same 5mm plywood in a 4 or 6 inch grid. While the rigid insulation alone would provide some support, poly-iso alone would probably be about 1/4 the strength of the torsion box I created. XPS alone would be better, and probably good enough, since it has more compressive strength. Real stressed skin panels use higher density foams than those designed for insulation. Higher density decreases insulating value but is necessary to achieve high strength performance. XPS is typically available in 1.5 and 2.5 lb per cubic foot densities. The latter is used under concrete to isolate it from the soil and would be a choice that could probably achieve 1/2 the strength of my torsion box. This build is an experiment in achieving the maximum performance possible for a bigger box for a military 6×6 I have.
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