At the start of the project, like everyone who reads Ulli Dolde’s book, I wanted to buy an FM2 shelter. But since these shelters are relatively small and by now ridiculously overpriced, what I think is the better option slowly came into focus: a GRP box.

To save money and because I love a challenge, I decided to build the box myself. After some research and many helpful tips, two companies emerged as possible suppliers for the panels: Stadur and Paneltec. In the end I chose Stadur – but only because of the delivery time. Paneltec made a great impression and is certainly the better partner, as they specialise in GRP boxes. Stadur only supplies the material.

The panels of the box are only glued together. No screws. I used Sabatack 750 MS as the adhesive. With these one-component adhesives it’s important that the bond line is 3 mm thick so the adhesive can cure properly. For this, I cut plastic washers and inserted them as spacers.
Then the adhesive was applied. Since this process was quite stressful, there are sadly no photos of it ...

To finish the box, the aluminium angles on the inside and outside edges are still missing. They are glued on and stabilise and stiffen the final box. They also keep water out.

A special profile is made for each corner of the box. For this, the profiles had to be mitre-cut. With a band saw and later a mitre saw with an incredibly expensive aluminium blade, that worked very well.

to be continued ...

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