B737 Sidewalls From Fiberglass

How we made it and why

First steps

To get started with the sidewall we need a good foundation

First thing to get started with the sidewall build was to make a platform to build the sidewall on. This we decided to do out of steel so it would be strong (and also elevate the floor since the yoke needs to fit under the structure).

Then it was off to the races. First we installed couple layers of different carpets to insulate and protect the floor. Then we got to work with the actual wall. It was made with this 3mm thin fiberboard and 40x40mm lumber. This in combinations with the upcoming fiberglass would make sure the sidewall will last all the beating it might experience during use and transport.

Fiberglass applied

Now that we had a good foundation it was time to get fiberglassin'

The fiberglass was quickly laid (since there isn't a slow way to do it or it will harden incorrectly) and we could see the wall take it's final form. After we gave it time to harden we realized it needed way more sanding and additional work than we thought. Not only did we have to sand it, we also added a lot of filler to make the surface smooth and good looking. This added about two weeks of extra time including the many layers of paint.

Fiberboard Installed

After the wall started looking more like a wall, we start thinking about the fiberglass.

Not too long after the first panel was installed our sidewalls were already looking good. Many might ask: why not just leave it there and add some paint. That would be quite a bad idea since the wall was built to last only as long as it had to survive till the fiberglass would be securing it. Since fiberglass needs a back structure to support it, it was mandatory to build something behind it. This structure was not meant as a final solution or to be used as is.

Final result

Was it all worth it? Is it any better than a wall made of plain MDF?

YES! The final result turned out a thousand times better than we could have ever hoped. Not only did it have a cool texture, it is also so strong you can literally jump on it and it's not going anywhere. Only thing left was the few plastic parts and it was done. There is a certain learning curve to working with fiberglass and the sidewalls as a first project might have been a little difficult. Regardless, we did it and would recommend others to try as well. It's surprisingly cheap and creates super light weight parts with insane strength.