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FWC Bronco to "Hawk" Build

bronco hawk diy build homemade frame

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#11 jcr5155



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Posted 29 April 2019 - 11:53 PM

Got the camper skinned this weekend. Picked up these 0.04 charcoal gray aluminum sheets from a place here in Denver, H&H Metals, would definitely recommend $90 per sheet and I used 3. I think these older campers used 0.024 or 0.03 aluminum, this new stuff is thick!

Cut out the shapes using a sheet metal blade on a jig saw, it went much better than I could have hoped! The hardest part was getting the window holes cut out just right. 


I placed insulation between the aluminum siding and the frame to reduce conductivity through the aluminum. I remember someone mentioned this on another forum in WTW. I plan to use 1" rigid foam insulation between the frame tubes. 

I used rivets at the main corners to hold the sheet in place since they sit relatively low profile and shouldn't impact the trim and butyl tape seal. The trim is screwed in approximately every 6", so these sheets will hold the camper tight. I didn't worry about putting silicone on these rivets, since they'll be covered by the trim and the butyl tape, any thoughts on this?


I sanded down the bigger pieces of trim to reuse them, but during demo I bent the shorter pieces and plan to just order new ones. Couldn't think of an easy way to get new 20' trim pieces home from themetalcompany here in Denver (I was told they sell the 20' pieces for roughly $20 depending on the shape), also this was a great way to save money in the build.


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#12 Wandering Sagebrush

Wandering Sagebrush

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Posted 30 April 2019 - 01:26 PM

Nice progress!
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Under the rocks are the words,
and some of the words are theirs 

Also tagged with one or more of these keywords: bronco, hawk, diy, build, homemade, frame

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