Fiberglass Composite Create Van Camper In Simple Steps

The best base for a motorhome is fiberglass. The material consists of fiberglass impregnated with polyester or epoxy resin.Because of its unique structure, fiberglass combines lightness, strength, durability, and high resistance to adverse external effects.Primary features of fiberglass include:High strength at minimal thickness.Thus, a 2 mm fiberglass sheet matches or sometimes exceeds the strength of 6 mm plywood.Resistance to dampness and rapid temperature changes.The material resists moisture, does not rot, swell or crack when heated.Ability to fabricate complex and bent elements.Compared to plywood and MDF, fiberglass easily forms any curves and shapes, enabling ergonomic shower trays, rounded furniture edges, and custom parts.Light body mass. Such weight reduction helps decrease the motorhome mass, vital for fuel economy and safety.Long service life. With careful handling, the lifespan reaches 50–100 years or more without substantial damage.Limited lifespanPlywood.If conditions are poor (moisture + heat + no protection), up to 12 months with leaks.With dampness, plywood lifespan reaches up to 2 years.When using waterproof plywood with condensation and heat, the service life may reach up to 5 years.Under best conditions, including waterproof plywood with varnish and constant ventilation without condensation and heat, lifespan reaches 10 years.With condensation and leaks, lightweight plywood is prone to delamination and mold within 12 months.If waterproof glue and varnish are used and coating is undamaged, plywood lasts up to 5 years.In favorable conditions: varnish, ventilation, and moisture protection — plywood lasts up to 8 years.Lightweight plywood is a wood-based material that absorbs moisture, and even waterproof plywood can hold water, resulting in mold after one season.MDF can deteriorate already after 6 months,water-resistant MDF has a lifespan up to 2 years,varnish-coated water-resistant MDF lasts up to 3 years,High temperatures severely damage MDF; at +50 °C glue loses strength and delamination begins,In best conditions — no heat, varnish protection and ventilation — lifespan reaches 7 years,Material is not the best, but widely applied because of production and processing convenience.ABS plastic can last from 1 to 2 years with intensive use,high temperature is generally the reason,at +60 °C mechanical strength begins to decline and intense degradation occurs with frequent heating to such or higher temperatures (often in summer),with not very aggressive use but considering its location inside a van, the plastic can completely lose its strength in just 6-7 years.Fiberglass does not swell or deteriorate when in contact with moisture,not afraid of vibration,and in the harshest conditions lifespan can reach up to 30 years.The minimum lifespans are indicated by me, and the maximum, assuming you mostly don’t drive, won’t exceed +50%.The easiest way to explain fiberglass: yachts have been sailing the seas for decades and are made of fiberglass.Capability to form non-standard shapes.Plywood, lightweight plywood, and MDF are characterized by low flexibility.Creating non-standard shapes requires costly and complex processing methods, or they are simply not feasible.In essence, ABS plastic is an industrial production material requiring factory processing.Panels can be clad by purchasing flat sheets, but this will be very expensive.Furthermore, ABS plastic stands out for its strength in very thin forms.But ordinary tools do not suit joining thin sheets.For self-builders this material is considered one of the least favorable.Fiberglass gives the ability to create any curved parts by yourself,which plays a key role in optimizing space and organizing functional zones inside the motorhome,but there are nuances concerning manufacturing and production costs,prices can be high or below those of plywood.Why fiberglass is the best choice for DIY conversions?The main constituent is fiberglass impregnated with polyester resin, granting parts strength and beneficial properties,which makes it indispensable for craftsmanship work:Ease of processing: the material is flexible before curing and durable afterwardSpace optimization by creating curved and non-standard shapes that eliminate bulky corners and save space.For example, it is possible to make a fiberglass shower tray precisely to the vehicle’s dimensions and shape,side openings on vans typically covered can be made alike, leaving more room,this creates the possibility to install the bed at the topmost level, not possible with plywood or MDF.Resistance to vibrations and shocks.While driving, the vehicle experiences constant vibrations, but fiberglass does not crack or chip.While other materials do not withstand vibration, fiberglass does not react to it.Minimal tools and training materials needed, no professional machine shop or complex equipment required, just basic tools and access to tutorial videos.A short explanation with a tutorial video: most fiberglass videos target mass production, where a mold for one part costs as much as the entire motorhome finish.However, there are methods allowing this to be done 20 times cheaper than plywood finishing, but they are not talked about.These methods are cheaper than plywood finishing but almost no one talks about them, though I know these ways.Down below, I will provide a source where you can check out this method,Read carefully to the end to find the name of my YouTube channel.Manual execution is not inferior to factory, you can do exactly the same as in production.Brief summary and recommendationsFor self-construction of a motorhome or conversion of a van into a passenger bus, fiberglass is the most rational optionWhy exactly rational, you ask?Because buying factory products 30-50% more expensive, you acquire durability and won’t see rot in 5-10 yearsHowever, it is possible that you encounter a homemade motorhome made of MDF, and if you go for six months to a hot country, returning you find the interior completely ruinedThis really happens — I have seen paneling replaced after 3 years due to mold and rust on fastenersThis is the most irrational approachOften self-builders believe that plywood can cover a motorhome in a couple of weeksWithout knowledge and recommendations, self-building often drags on for several yearsAnd there were even cases, mainly with MDF and light plywood, when self-construction lasted more than 3+ years and then everything was started anew because the material was spoiled by heavy moisture.I did not write how long construction takes with different materials because it depends only on knowledge.Many neglect knowledge, just buying expensive tools thinking it’s enough.The truth is knowledge is always paramount.As an example, info on working with ABS plastic is easy to find, but tools are very expensive and meant for large-scale production.There are many tutorial videos on other materials, but how useful will it be?.Big expenses will be only for tools.Plus, you will have to study hundreds of videos about working with the tool.Moreover, working with the material can cause injuries from a circular saw.There are nuances about fiberglass that I mentioned earlier and that few people know,Such information is not on the internet, but I have a video on YouTube,Watch the video, maybe you’ll want to master and build a motorhome yourself once and for all,Look for me on YouTube by typing (@) and the channel name (HardRefit), I won’t continue praising fiberglass, the choice is yours,I was very precise and indicated the maximum lifespan under different operating conditions.If you need a contractor for van-to-motorhome conversion, we are at your service,The website link is posted in the description of our YouTube channel.I hope my recommendations assist you in choosing the material for building a motorhome,I would be grateful if you like the article and subscribe to our YouTube channel.