New floor Construction

[charliem]

[font size="3"]@djmiller ,

Can you provide insight into the construction of the new floor? I have long thought that a floor could be constructed using aluminum, foam, and composites to yield a strong and insulated floor while retaining the corrosion/rot/mold resistance of the original LL philosophy. As an engineer and vocal critic/cheerleader for LL I'm very interested in new features and construction.

Thanks for your participation in our forum.
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[djmiller]

Charlie

FLOOR CONSISTS OF 1-1/2" X 1-1/2" Aluminum Frame and cross members, openings between the aluminum tubes are filled with 1-1/2" 2 Lb. Lamination grade foam board. The top side has a layer of lami-plast, which is a Glasfibre Reinforced plastic. One the bottom side a 2.7mm sheet of Azdel covers the 2 lb. foam, with a final layer of black tuff tear.  This assembly is vacuum bonded and the Vinyl floor covering is applied to the assembly.

For clarification purposes vacuum-bonded is NOT your ordinary lamination process through glue rollers.  Glue is consistently applied though a machine driven manifold at a constant speed and rate and the assemblies are not run through a pinch rollers but sandwiched under consistent pressure using vacuum bags.

[charliem]

[font size="3"]dj,

Thanks for the detailed reply. Sounds like a great solution to the no rot no mold yet still warm floor problem. I wish I had it.

What is the cross member spacing?

Now if you could only export this technology to Airstream I know a lot of new 'Streamers would be happy.
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[djmiller]

It Depends on the unit but basically broken into 3 sections Front, Rear, and the center where the axles are attached. A box around each area with two additional runs spaced evenly down the center of the frame, with  a couple of additional cross members that are used as backers for cabinets.  I don't know what we are advertising but I would say maybe R7 to R8.  Much better that the raw aluminum floor and should lighten up the units a bit.

[charliem]

[quote timestamp="1480966122" author="@djmiller" source="/post/26256/thread"] .......... R7 to R8.  Much better that the raw aluminum floor and should lighten up the units a bit.[/quote][font size="3"]Yes, especially when you consider the weight of the rubber foam squares most of us have added. [/font]

[djmiller]

HA

[drdave]

I'm happy with mine, but have noticed one spot in the bedroom that squeaks if I step in just the right spot. That said it's a very minor complaint and I still give it a solid thumbs up.

[docktorjj]

DjMiller,

Can some pictures be posted of the process and materials?

[pinstriper]

[quote timestamp="1480966693" source="/post/26257/thread" author="@charliem"]

.......... R7 to R8.  Much better that the raw aluminum floor and should lighten up the units a bit.

[font size="3"]Yes, especially when you consider the weight of the rubber foam squares most of us have added. [/font]
[/quote]That would be....umm....maybe 4 pounds ? 2 packs of foam from HFT, and they are feather light.

[djmiller]

I would love to if I had the time  The next time I do get to Lamination I will see what I can do.