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Flat Panels & DIY Campers
FDL operates one of New Zealand’s largest flat moulds, measuring 16.8 × 3.8 m, which enables us to manufacture large fibreglass sheets and sandwich panels, custom-made to suit each customer’s requirements. We offer a wide range of panel cores and finishes, and can incorporate structural elements such as alloy ribs for lifting, fixing or mounting points.
We also repair fibreglass panels and damaged truck or camper bodies, and refurbish truck-body interiors. This includes repairing floors and applying a new non-skid coating to suit your requirements. To discuss your project, call us on 06 323 0960 or complete our contact form.
Applications
FDL fibreglass sheets and sandwich panels are suitable for a wide range of applications, including:
- Truck bodies
- Refrigerated bodies and enclosures
- Horse floats, caravans and campervans
- General-purpose and car trailers
Panel Cores
A variety of cores are available for our panels depending on your required end use:
- Fibreglass only (no core)
- Translucent (no core)
- Plywood (4mm - 30mm)
- Insulated foam: styrofoam and polyurethane (PU), PET
- Insulated structural panel (ply/foam/ply): minimum foam-core thickness depends on the core material. Styrofoam cores are generally no thinner than 20 mm, while some specialist cores can provide insulation and structural performance at thinner dimensions.
- High-tech core: balsa, honeycomb and PVC foam for lightweight and high strength specialised applications
Panel Finishes
Our fibreglass panels can be manufactured with a smooth, high-gloss surface on one or both faces. The following finishes are available:
- XMO: High-gloss gelcoat on the front face, with bare-faced ply on back
- XM1: High-gloss gelcoat on the front face, with a textured laminate on back
- XM2: High-gloss gelcoat on both faces
- Non-skid: A variety of non-skid surface finishes are available to suit different applications
High-gloss white gelcoat is standard. Other colours are available on request—see the Colours section below for more information.
Edges not gelled (default)
Edges gelled on request
Non-skid Finishes
Choosing Between Styrofoam and Polyurethane
FDL generally recommends styrofoam cores for most applications because they offer low water absorption, low weight, good compressive strength and lower cost.
Polyurethane (PU) provides greater thermal insulation and is recommended for cold-storage enclosures. Where PU is required, FDL injects the foam between ply skins held in a high-strength press, producing a strong bond between the core and the panel skins.
Panel Extras
Colours
A wide range of colours can be incorporated during manufacture by adding pigment to the gelcoat. Because no additional finishing or painting is required, this can also reduce the overall cost. Soluble dyes can be used where a translucent finish is required.
FDL does not recommend dark colours because they absorb more heat. Excessive heat can cause post-curing, in which the resin shrinks and the glass fibres become more prominent, changing the smooth surface to a textured appearance. In extreme cases, it can also cause delamination between the panel layers.
If you intend to paint your panels, please talk to us first so we can discuss the available options and determine the best approach for your project.
Warranty notice: FDL does not provide a warranty for panels painted a dark colour without prior consultation. Even when discussed with us beforehand, the use of dark colours remains at the customer’s risk.
DIY Campers
There are several panel constructions suitable for DIY camper projects. The best option depends on the intended design, whether the camper will have a supporting frame, and where fixing points, doors, windows and services will be located.
Framed construction
Fibreglass-only skins and panels with thinner plywood cores of 4–12 mm generally require a supporting frame. FDL has successfully supplied both 3 mm fibreglass-only skins and 4 mm XM1 panels for framed camper projects.
One consideration with 3 mm fibreglass-only skins is thermal expansion. On hot, sunny days, the fibreglass can bulge between supports—an effect commonly known as “tin canning.” A 4 mm XM1 panel is more dimensionally stable and is less susceptible to this effect.
Structural plywood-core panels
Panels with thicker plywood cores can provide sufficient structural strength without requiring a separate frame. These panels can be supplied with either an XM1 or XM2 finish.
Insulated Styropanels
For DIY camper construction, insulated panels generally use a styrofoam core at least 20 mm thick. A typical panel has a 2 mm fibreglass skin bonded to each side of the core.
Plywood can be incorporated beneath the skins where fixing points are required. Alternatively, the inner fibreglass skin can be omitted to produce a fibreglass/styrofoam/plywood construction with exposed plywood on one face.
FDL can also incorporate wiring conduits, localised timber around windows and doorways, and reinforcement for other fixing points. This produces a highly structural panel system with excellent insulation. The most commonly requested construction is a 2 mm fibreglass skin, 35 mm styrofoam core and 2 mm fibreglass skin.
Bending panels
Fibreglass-only and thinner plywood-core panels have limited flexibility. Where bending is required, it should be completed as soon as possible after manufacture. As the fibreglass continues to cure, it becomes more difficult to bend without cracking the gelcoat.
Panel FAQs
Panel is costed by size, not by square metre.
16.8m x 3.80m.
No. All panels are made to order and therefore not restricted to a standard size.
Ply core thickness ranges from 4mm minimum to 30mm maximum.
A panel with a 4mm ply core and XMO finish (gelcoat one face, barefaced ply the other) will have an approximate 6mm overall thickness, and 25mm ply core panel with an XM2 finish (gelcoat both sides) will have a 30mm overall thickness.
Insulated foam core thickness ranges from 15-150mm, however we generally prefer not to go below 20mm as the styrofoam begins to lose consistency in thickness.
A 15mm non-structural (no ply) XM2 panel will have 20mm overall thickness
The lead time depends on what is currently in production, quantity of panels ordered, and the type/finish of the panels, so the lead time will vary.
Panel manufacture will take 1-3 days, depending on panel core and finish, and 1-2 days to QC, perform any gel repairs, and prep for despatch.
A freight estimate can be provided after the delivery address and panel size/type is confirmed.
We generally use Mainfreight with panels that do not exceed 2.400m in width and can be comfortably transported on a pallet. For longer panels that exceed 2.4m in width, we hire a freight company with a flat panel truck, where the panel is supported by dunnage instead of a pallet.
Panel & DIY Camper Gallery
Explore examples of FDL flat panels and completed camper projects to see the range of constructions, finishes and applications available.
