RV FEATURE
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BUILDING CRUSADER
A couple of things stood out as we were shown through the Crusader factory . I was particularly intrigued by the company ’ s method for joining the wall panels to the one-piece floor and roof . Each side panel is CNC-routed by Creative Composites before delivery . They have a single protruding ‘ tongue ’ on the top and bottom . These tongues lock into a notch routed into the floor and one-piece roof sections . This system guarantees that the wall panels will be accurately located . The walls and roof are 30mm panels comprised of outer layers of fibreglass and an XPS closed cell foam core .
The panels , roof and floor are also routed with screw holes . But how do these screws guarantee strength and stability when
they ’ re only biting into the closedcell foam core of the sandwich panels ? Well , it ’ s not only the screws doing the work : Crusader uses a special MS Polymer adhesive that ’ s also used by a major truck manufacturer to forever bind the structure of the caravan . The screws merely ensure a tight fit while the adhesive cures . Interestingly , Crusader manufacturers its own screws for this purpose .
It ’ s the same deal with the internal cabinetry . Were you to peak inside the overhead cabinets of , say , a CRV , you ’ d see screws ; however , their chief purpose is to hold the cabinets in place while the adhesive goes off . The rest of the furniture is self-supporting , though it ’ s further secured by the adhesive .
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