Stunning Stucco Finish on Spray Foam Exterior!

Today is the day we've all been waiting for: I have FINISHED the stucco on the exterior of the World's First Spray Foam & Stucco Motorhome!

In the end I decided to go with a cream towards the top, a beige swirl pattern finish on the bottom and a blue grey in the dados. For your viewing pleasure, I present *drumroll* the finished look!

The Finish Line is Near!

One of my guys and I spent the morning doing the base coat on the exterior of the motor castle. We apply it directly to the planed flat spray foam using a structural grid material. Base coat is great to perfect the final appearance, fill low spots and mold flaws.
I'm spreading the base coat on with a small trowel.
Here I am trimming the grid work to cover the surface.
Sometimes I need to build custom tools to get the job done. This tool is to perfect the base coat application in the dados.
Here is a close up of the detail work around the wheel well.

Finally, Spray Foam Complete!

After simply heating, for about an hour, the exterior of the metal motorhome to the proper temperature for successful spray foam adhesion, I have completed the first phase of my patented Masterbond-SP exterior wall system: application of closed cell spray foam insulation. Here are a few images of the dried foam.


That's me at the end.

Under the Big Tent

All proper castles have tents in their courtyard hiding the wonders of the world within. The bearded lady...the snake man...the world's first stucco motor castle!

I had to do a little rearranging of vehicles etc. to accommodate the final phases of my stucco motorhome. Taking down the neighbor's fence was not an option. So, the souped up van I had in a car show years ago, was loaded onto a flatbed and moved to my warehouse, my large foam truck I take to jobs is parked in the street and the motor castle is now centered in my driveway.

Once in place, the winter weather approach of spraying foam insulation had to be set up. When I do exterior spray foam insulation jobs in the winter I tarp over the entire space as I need to heat the air and the surface to a certain temperature so the foam adheres correctly. This is surprisingly much easier than you would expect. It took about an hour to get the metal exterior walls of the motorhome to the desired temperature.
Boy I would hate to be my neighbors. At least I'm adding a little color to an otherwise bleak winter landscape!
I've set up a couple of stories of staging so I can easily spray the top of the motorhome.

Final Preparations for the Spray Foam & Stucco

I can actually see the end in sight on the stucco motor castle project. This week I applied the final metal mesh finish along the bottom edge of the motorhome which will become part of the structure as I am spraying foam and applying stucco. Once the temperatures warm up a little (we've been in the teens all week) I will begin spraying foam. Here are a few pictures of this stage of the project.

I attached a hand curved metal mesh along the bottom edge. It also has foam board dams attached to it.

Above the compartment, is a 6" x 10" block which is a sample of the wall system I intend to apply. Take a look at the sample and in your mind, replace the plywood with the metal exterior of the motorhome! Also, this compartment and all other exterior components have been built out to accomodate for the thickness of the spray foam. I actually had my buddy machine me a few mounting brackets for some of the components.

Dams are applied around all windows and structural edges.

Now if only I could get the neighbors to take down the fence!

Prepping the Exterior for Spray Foam

Now that the inside is nearly finished (final paint job, laminate flooring and carpeted ceilings is all that remains for the most part), it is time to prepare the exterior of the motor home for the application of exterior spray foam and stucco.

I'm going to use my patented Masterbond SP wall system. This system of exterior spray foam is extremely energy efficient. Basically, you are wrapping the building in foam creating a seamless barrier to moisture and the elements. Masterbond SP is super adhesive and can be applied to almost any dry sound surface - wood, metal, cement, brick etc. For more detailed information on the Masterbond SP wall system and my patents, visit my website www.sprayfoamstucco.com

Here is a video detailing the Masterbond SP Exterior Spray Foam and Stucco Wall System Process:

(Also available on YouTube.com )

I've begun the preparations on the exterior of my motor home. This includes scuffing the surface to make it rougher and easier to adhere the spray foam to. This is the same principal used when applying paint or varnish to wood; it simply makes it stick better.

I've also removed and blocked off a door and window as you can see. All remaining windows and doors will be treated with dams to hold the foam back. This is going to be a very energy efficient, warm or cool motor castle!