Composite Hallmark on '07 Tundra
POSTED: March 2, 2007 | by Staff Writer
For 2007, Hallmark has announced a line of composite pop-up truck campers. The new pop-ups are pre-moulded composite body and frame campers. Their walls were designed and built in a joint effort with CF Maier a company known for building race car bodies and the Earthroamer.
"My brother, father, myself and two long-time employees spent most of 2005 and half of 2006 building each model and mould by hand. These campers are completely built out of hand laid fiberglass much the same way today's fiberglass boats are built," explains Matt Ward of Hallmark.
To build the new Hallmarks, gel coat is sprayed into a mould and then hand laid fiberglass is put down. After that a resin sealant and strengthener is applied. Following the resin and sealant, a composite layer of end-grain balsa wood is applied. Then the form is completed with a second layer of hand laid fiberglass and a final coat of resin sealant.
"The balsa wood is very light and strong. It's used in the 2007 Corvette bodies. The result of all this is a free standing body and frame combination that will not rot, de-laminate, or fade. And it's very strong and extremely nice looking," adds Matt.
Behind the camper wall and frame is 1" of insulation and then wood backing for cabinets.
"We use a three layer insulated soft wall on all of our pop-ups made out of a special material that will not mildew or crack in cold weather. As a result, our pop-ups are good to 70 degrees in -20 degree weather," said Matt.
Every Hallmark camper is manufactured at their facility. Hallmark will even make a camper from carbon fiber if a customer is willing to cover the extra material cost. The result would be an even lighter and stronger camper.
"We make everything in-house from the cabinets, cushions, and soft-walls to the floors, roofs, and carpets. We also boast the only patented worm gear electric roof on the market. This system will lift 400 pounds (181.5 kilograms) in addition to the weight of the roof and is extremely reliable. 50 years in the making, I'm sure Hubert M. Ward would be proud of our latest product," concludes Matt.
For more information about Hallmark and their line of composite pop-up truck campers, visit www.hallmarkrv.com.