Cotton-Fiberglass Composite Makes Lightweight RV Countertops
The technique is very similar to the sort of moldless composite work Burt Rutan pioneered in aircraft use. The fiber-reinforced plastic is formed around a positive ‘buck’ that remains inside the final part, adding stiffness and some backing. Unlike Rutan’s designs, which used pure Styrofoam inside, [Whitburn] is using a sandwhich of two layers of thin ply (3.6 mm) with XPS foam in between.
- ▪The technique is very similar to the sort of moldless composite work Burt Rutan pioneered in aircraft use.
- ▪The fiber-reinforced plastic is formed around a positive ‘buck’ that remains inside the final part, adding stiffness and some backing.
- ▪Unlike Rutan’s designs, which used pure Styrofoam inside, [Whitburn] is using a sandwhich of two layers of thin ply (3.6 mm) with XPS foam in between.
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| Original publisher | Hackaday |
| Canonical URL | https://hackaday.com/2026/08/10/cotton-fiberglass-composite-makes-lightweight-rv-countertops/ |
| Publication time | Mon, 10 Aug 2026 23:00:30 +0000 |
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Cotton-Fiberglass Composite Makes Lightweight RV Countertops No comments by: Tyler August August 10, 2026 Title: Copy Short Link: Copy You’ve seen fiber-reinforced-plastic before, no doubt, but perhaps never quite like in this video by [Whitburn Studio]: it’s still got the usual resin, but instead of glass or carbon fibers, he’s using printed Japanese cotton to create strong, lightweight and good looking parts for the interior of his RV– specifically the countertops. The technique is very similar to the sort of moldless composite work Burt Rutan pioneered in aircraft use. The fiber-reinforced plastic is formed around a positive ‘buck’ that remains inside the final part, adding stiffness and some backing.
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Excerpt limited to ~120 words for fair-use compliance. The full article is at Hackaday.
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