The design is simple and efficient...
We take lengths of 50x50mm (2"x2") batons and cut them into the prescribed lengths and they are stored in designated slots on racks.
They are used to make 5 different sized panels which will make the shelters structure when joined.
To make these panels we then use a template or 'jig' of an existing panel and place the correct lengths in place on the jig using it as a guide. When the correct lengths are in position they are joined with 80mm screws and 90mm nails to form a skeleton frame.
These are then clad in 10mm ply or waterproof chipboard. The first version of the shelter was clad in a plastic wrapping which formed the outer wall. But we are now in a position to give the structures a solid wall, which adds security and warmth to the structure.
The panels are then given an outer layer of tarpaulin type material to protect the wooden frame and panelling from the elements.
Finally the panels are lined on the inner surface with insulation to retain heat. We have been experimenting with different insulations, and often with what is available at the time. These include silver foiled bubble wrap, more comprehensive 7 layered professional foil insulation, a 10mm carpet type of material made from recycled clothing, and occasionally more common place solid foam insulation when we can source it.
Finishing touches of ceiling and floor level adjustable vents are fitted to combat condensation and build up of dangerous gases resulting from indoor cooking with gas hobs. Doors are also pre fitted to the front panels with locks and padlocks.
The flat pack shelters are then ready to be collected for transportation to site where they are assembled and habitable between 1-2 hours.
Please feel free to look at our designs, if you wish to use these to build your own please do so, the more people building shelters the better.