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Laying out and cutting the 12mm Divinicell foam for new roof construction.On top of this we will make a new laminate with four layers of fiberglass and polyester. | We are using a material called Divinicell. It's made up from little sqares of foam attached to a fiber web. This material gets very strong at a relative low weight because the polyester will form as vertical "walls" between the bricks. | We are using filler made from polyester and industrial talcum to seal off the edges of the foam. If this is not done before laminating starts the polyester will flow out of the foam and down the coach side. | Making the curve from sidewall to roof is quite a challenge and I hope I got this right. |
19/01 Today we laminated left side of the roof. Here we are cutting the materials for 4 layers of fiberglass. Ends are cut in steps to make edges and joints smooth. | It took two of us four hours to lay this. No coffebreaks as the polyester hardens so fast you can not stop before completed. | The added weight of this new roof was estimated to be 120 kg. We spendt 45 kg of polyester only on this side so estimate seems quite accurate. | So far so good. |
26/1.08 This week we have done the complete roof laminate. Worst part of the job is sanding this down. We need a straight but rough surfac before spraying the gelcoat. | After countless hours of sanding I could start marking up the low spots and cutting material to build up with more laminate. | Each layer of laminate builds 0,8 millimeters in height so one can calculate how many needed. But all this laminating and sanding takes a lot of time and patience. Also me beeing a total novice on this makes things even slower. | Second time of laying laminate in low spots. The goal is clear; no cheating with thick layers of bondo on this coach. |
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