Flat Panels & DIY Campers
We are home to one of New Zealand's largest flat moulds, at 16.800 x 3.800m, which gives us the upper edge in making larger size flat fibreglass sheets/sandwich panels. All of our panels are custom made to the customer's requirements. We have many different types of finishes and a variety of core products we can use. Structural elements, such as alloy ribs for pick-up/mount points, are also available.
We can also repair panels and damaged truck/camper bodies - give us a call on 06 323 0960, or fill out our contact form here.
Applications
Fibreglass panels have a range of applications:
- Truck bodies
- Refrigeration
- Horse floats, caravans and camper vans
- Personal trailers and car trailers
DIY Campers
There are many types/combinations of panels that are possible. Each has its own advantage and application, and the choice of which will depend on if you have given any thought to how you are going to approach your project. Fibreglass-only skins and the lower thickness ply cores (4-12mm) usually require a frame to support them. We have provided many 3mm fibreglass-only and 4mm XM1 (see 'panel finishes' below) panels for such projects with great success.
However, a word of warning on the 3mm fibreglass only skins. Fibreglass has a very high rate of thermal expansion, so on a sunny day, you can get an effect referred to as “tin canning”, where the panel will bulge between supports. A 4mm XM1 in contrast will not display such a trait and remains fairly stable.
As you get into the thicker ply for the fibreglass panels, they become structural and don’t require a frame. These can be supplied in both XM1 or XM2 finish.
The top of the line are our styropanels, which can have an overall thickness of 20-125mm. Normally, these have a 2mm fibreglass skin glued to a styrofoam core. Ply sheets can be added under these skins if fixing points are required and/or the inner skin can be left off to have a fibreglass/styro/ply composition leaving bare ply on one face. We can also incorporate conduit for wiring looms, localised timbers for windows and doorways, and any other fixing points you may require. This is a very structural system and of course, you get great insulation as well. A 2mm fibreglass/35mm styro/2mm fibreglass combination is the most common requirement.
Bending panels
The fibreglass-only and thinner ply-core panels can flex a little bit, but not a great deal. If bending is required, this needs to be done as soon as possible as the longer you wait, the more the fibreglass cures, and the more difficult it will be to achieve the desired shape without cracking the gelcoat.
However, a word of warning on the 3mm fibreglass only skins. Fibreglass has a very high rate of thermal expansion, so on a sunny day, you can get an effect referred to as “tin canning”, where the panel will bulge between supports. A 4mm XM1 in contrast will not display such a trait and remains fairly stable.
As you get into the thicker ply for the fibreglass panels, they become structural and don’t require a frame. These can be supplied in both XM1 or XM2 finish.
The top of the line are our styropanels, which can have an overall thickness of 20-125mm. Normally, these have a 2mm fibreglass skin glued to a styrofoam core. Ply sheets can be added under these skins if fixing points are required and/or the inner skin can be left off to have a fibreglass/styro/ply composition leaving bare ply on one face. We can also incorporate conduit for wiring looms, localised timbers for windows and doorways, and any other fixing points you may require. This is a very structural system and of course, you get great insulation as well. A 2mm fibreglass/35mm styro/2mm fibreglass combination is the most common requirement.
Bending panels
The fibreglass-only and thinner ply-core panels can flex a little bit, but not a great deal. If bending is required, this needs to be done as soon as possible as the longer you wait, the more the fibreglass cures, and the more difficult it will be to achieve the desired shape without cracking the gelcoat.
SEE BELOW FOR MORE INFORMATION
Panel Finishes
Our fibreglass panels are finished with an extremely high gloss, smooth surface available on either one or both faces and can be ordered under the following abbreviations below.
- XMO: High-gloss gelcoat on front, bare-faced ply on back
- XM1: High-gloss gelcoat on front, textured laminate on back
- XM2: High-gloss gelcoat on both sides
- Non-skid: A variety of non-slip surface finishes are available, suitable for either flooring or decking
Non-skid Finishes
Edges not gelled (default)
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Edges gelled on request
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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 - 25mm)
- Insulated foam: styrofoam and polyurethane (PU), PET. All insulated panels have an XM2 finish
- Insulated structural panel (ply/foam/ply): 20mm and above overall thickness, 15mm minimum foam thickness
- Hightech core: balsa, honeycomb and PVC foam for lightweight and high strength specialised applications
Styrofoam or Polyurethane?
While polyurethane was the foam of choice due to its greater thermal insulation performance, we have transitioned to the preferred styrofoam cores, which has a lower thermal resistance but excels in other areas:
For cold storage enclosures, Polyurethane is recommended, as it has the highest R-value (heat resistance) of any insulation. When PU is required, FDL uses a unique system which bonds the ply skin to a polyurethane core. Foam is injected between the ply skins while locked in a high strength press. This results in the density of the foam increasing from the centre outwards, to where it forms a high strength bonding layer to the skin.
- lower water absorption rate, so ideal for applications where moisture or water is a concern
- lower density, making it lighter and easier to handle and install
- higher compressive strength, so better suited to load-bearing applications
- less costly
For cold storage enclosures, Polyurethane is recommended, as it has the highest R-value (heat resistance) of any insulation. When PU is required, FDL uses a unique system which bonds the ply skin to a polyurethane core. Foam is injected between the ply skins while locked in a high strength press. This results in the density of the foam increasing from the centre outwards, to where it forms a high strength bonding layer to the skin.
Pigments
Almost any colour can be incorporated into the product during manufacture by pigmenting the gelcoat. Cost is reduced by using this method as no further finishing, or painting is required. Soluble dyes can be used if a translucent product is desired.
We do not recommend dark colours, however, as these produce excessive heat, which can lead to the surface deteriorating and exposing the fibreglass. In extreme cases delamination (separation of layers) can occur.
If you intend to paint your panels, talk to us first so we can discuss options best plan to meet your needs.
We DO NOT OFFER WARRANTY on panels that have been painted dark without our knowledge. Even with our knowledge, it will be at your own risk.
We do not recommend dark colours, however, as these produce excessive heat, which can lead to the surface deteriorating and exposing the fibreglass. In extreme cases delamination (separation of layers) can occur.
If you intend to paint your panels, talk to us first so we can discuss options best plan to meet your needs.
We DO NOT OFFER WARRANTY on panels that have been painted dark without our knowledge. Even with our knowledge, it will be at your own risk.
Panel Extras
We also have alloy upper and lower cant rails for refrigerated body panels, plus corner caps to suit.
