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Fiberglass Travel Trailer Shell Construction
The Two In One Factor
It takes four fiberglass shells to build an Oliver, two inner shells and two outer shells.
Molded Fiberglass RV
The lower outer fiberglass shell is first bolted to the aluminum frame. Then, some of the electrical wiring, all the plumbing lines, and the holding tanks are placed inside, and the connections are made.
Next, the "inner bubble" is created by bonding the upper and lower inside shells. The seats, counters, and cabinets are molded inside the "bubble" created by these two shells.
All the necessary holes are precisely cut into the "bubble". The cabinets are then finished with their lighted interiors and doors, adding a touch of functionality and aesthetics. More electrical wiring is added and connected, ensuring the RV is ready for use.
Finally, the 'inner bubble' is carefully and securely lowered into the waiting lower outer shell, marking the completion of our RV interior creation process.
Plumbing connections are made in the kitchen and bath areas, wiring is connected to the lower regions, and the upper outer shell is affixed to cap it all off. The series of pictures illustrates the process of producing each shell piece.
Mirror-Like Superior Finish
For a superior finish, we have to start with a clean and polished mold. Any imperfections in the mold will show up in the gel coat. In the picture, the finish is like a mirror.
High Grade Gel Coat
All the shells are constructed starting with a transportation-grade gel coat that resists chipping from road debris and rocks. A UV protectant is added to help reduce fading by the sun.
Hand Rolled
A skin coat of neat resin and chopped fiberglass is added and hand-rolled to remove any air pockets in the shell.
Reinforcement
A core mat is added to the roof and glassed in.
Additional Insulation
We add carbon core, a very strong honeycomb-type composite material, on top of the core mat. The air pockets in the carbon core also serve as an additional layer of insulation. You can see where we do the same for the walls where the windows and other attachments are to be installed.
Strength and Support
On the outer lower shell, the channels for the frame are hand-laid with two layers of woven mat and topped with a layer of bi-directional glass cloth. This adds strength and support to the area of the trailer where the frame and body come together.
Layering for a Bond
The same layering process above is used on all four shells in the areas where they will later be bonded together.
Mold Extraction
Once cured, the fiberglass shells are extracted from the mold, and the cycle starts again to produce another set.
Top Shell is Finished
The pictures above show the top outer shell being pulled. In the image above, you can see the location of the custom high-mount Oliver light.