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Ford Aeromax 120 RV Conversion


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7 hours ago, kilrathy10 said:

This is one outstanding piece of art in the making.... I look forward to more of this build... The biggest thing that makes it stand apart from just about every conversion I've ever built; the rounded edges and corners....

I'd love to get my hands on a bunch of half round styrene.... Where did you get that?? I can't find any of that stuff to save my life... 

 

1 hour ago, DZ7581 said:

I am interested in how you did your corners and what you used. I have a project which requires a similar corner and I have no idea how to do it.

Yes, the radius corners were a huge sticking point and the search for suitable material contributed to slowing the project down. Most all of these 1:1 conversions have a 5 or 6 inch radius to all of the corners, and that was a must for this project. 1/4” quarter-round is really hard to find.

25A7B858-0279-4B6C-8567-F352B4FFF966.thumb.jpeg.74838c45406243eb977c478613a0457a.jpegI finally found 1/2” half round from Plastruct, and ordered direct. It’s not styrene, it’s butyrate, Product number 90176. Still would require splitting it down the middle, of course. 

BF78D509-3F90-45A1-A074-44CEB150D8EF.thumb.jpeg.f4eaf5bea71a73b9215526e547cd89af.jpegI was about to start the project with that stuff, but happened upon an eBay listing for 3D printed truck sleeper frames.

I bought one frame, a 120” version with an angled front wall, (used part of it to make the bunk, and for below the floor line) and also asked the seller if he could make them longer, and he was happy to do so.

I sent him the specs I was looking for, a 1/24 scale 100” width and height, and 288” in length. The seller is thorloveseleanor. He doesn’t list anything like it now, but I bet he would still make them. There’s a market for stuff like this. Having the frame basically ready to go has simplified and made the build much easier and faster. 

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2 hours ago, vincen47 said:

 

Yes, the radius corners were a huge sticking point and the search for suitable material contributed to slowing the project down. Most all of these 1:1 conversions have a 5 or 6 inch radius to all of the corners, and that was a must for this project. 1/4” quarter-round is really hard to find.

I finally found 1/2” half round from Plastruct, and ordered direct. It’s not styrene, it’s butyrate, Product number 90176. Still would require splitting it down the middle, of course. 

I was about to start the project with that stuff, but happened upon an eBay listing for 3D printed truck sleeper frames.

I bought one frame, a 120” version with an angled front wall, (used part of it to make the bunk, and for below the floor line) and also asked the seller if he could make them longer, and he was happy to do so.

I sent him the specs I was looking for, a 1/24 scale 100” width and height, and 288” in length. The seller is thorloveseleanor. He doesn’t list anything like it now, but I bet he would still make them. There’s a market for stuff like this. Having the frame basically ready to go has simplified and made the build much easier and faster. 

Whoa!!! Thanks, Bud... I totally appreciate the info... This will, definitely, be worth some investigating... Awesome....

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16 hours ago, kilrathy10 said:

Whoa!!! Thanks, Bud... I totally appreciate the info... This will, definitely, be worth some investigating... Awesome....

No problem. And, your racing trailers are really nice - more stuff we all wish they made kits of.

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5 hours ago, oldr-n-drt said:

cary...yall are looking for 1/4 inch  half round ( .250 x .250)?? oldr-n-drt

Yeah, the closest thing to it I could find was 1/2 inch half round (1/4 inch radius, half inch diameter). 

I was able to find 1/4 inch quarter round wood, which I thought could be smoothed and used to create a mold and then cast resin quarter round. But, I eventually was able to find the 3d printed frame option, though it wasn’t cheap. 

Ideally, 1/4 inch radius quarter round plastic or resin would be needed if I wanted to make a bunch of these RV conversions and stacker trailers (which I do) economically.

Edited by vincen47
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Got more work done on the RV body, mainly below the floor line and the side door with the retractable step. I also made the interior window frames and shades. 

Next will come the roof and bay doors/lower trim. Lots of sanding and filling. But, I’m loving this project. I hope it’s the first of several enjoyable conversions.

602E976B-950F-4098-8C52-6C8FA5F4E48A.thumb.jpeg.5ff5d84137c97c71461416dc52fd0d16.jpeg5644EC24-7171-42CE-B895-86B28EE41C70.thumb.jpeg.f633754521c6fa6bbfe37312bf4c1a00.jpeg8A36F2EB-C5B7-48D3-A328-3A0C5956AC57.thumb.jpeg.5716b14cce2d2293a988c778e4791964.jpeg7488DD02-3517-4575-9273-15D54FCC551C.thumb.jpeg.55b0a71eb90e1f10ff318e2d9fa4790e.jpeg09BF22F8-44AB-4965-A1D7-4A018F971678.thumb.jpeg.29835f7d497bd70e083f7a64d01ba368.jpeg

AAAD6FEF-8026-421D-A906-409F001EAEB0.jpeg

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  • 2 weeks later...

Thanks guys! Another quick update...

Paint and decals are done, I think. Now I’m on the final lap with adding mostly rooftop parts, awnings, and the windows. There’s also few things to do on the cab and chassis before it joins the RV body.

34E47A46-C37F-498E-BD37-B1D8C9B6EE19.thumb.jpeg.4c4e5ce92ae4fa56b6c3e648f76e34c8.jpeg8DC8DF3D-4B7B-46E3-950C-7338C72C9C44.thumb.jpeg.333ff3fea4998e07fa84bd62168bd76a.jpeg

On a side note, I finally turned over the cutting mat. It was fairly new when this project started (and stalled), seen it’s share of glue drips and paint spills since.

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