Roof Upgrade

After much debate, I made a new carbon-fiber/foam composite sandwich roof for our camper. The original honeycomb cored fiberglass roof with aluminum outer frame that I made in the spring was fine, and it worked well, but I wanted to see if I could reduce the roof weight and simultaneously increase thermal insulation. The roof is a large percentage of the camper surface area, so increasing the roof thermal R-value is a good way to increase the overall camper cold weather comfort.

I just finished the roof, and it turned out 28.2% lighter than the original roof and the R-value is now around R4.5. It was a lot of fabrication time, but I think it will be worth it when traveling and camping in colder locations/seasons.

I made the new roof using two types of epoxy resin, three types of carbon fiber, and Divinycell foam core. For those that are interested, the following are photos that I labeled for each of the major fabrication steps.