Method of manufacturing a vehicle body

A method of fabricating an over-the-road vehicle, comprising:

• providing a chassis;
• providing an envelope, wherein the envelope comprises:
• a first continuous sheet of material folded over to form a front wall, an overhead panel, a back wall, and at least a portion of a floor panel;
• a second continuous sheet of material forming a left side panel;
• and
• a third continuous sheet of material forming a right side panel;
• sealingly connecting the left side panel to the first continuous sheet of material on a first side of the first continuous sheet of material;
• sealingly connecting the right side panel onto the first continuous sheet of material on a second side of the first continuous sheet of material;
• and
• securing the envelop onto the chassis;
• and wherein each of the first, second, and third continuous sheets of material are fabricated from at least one pliable fiberglass sheet.

A method of forming an envelope for an over-the-road vehicle, comprising:

• creating a design for a three-dimensional object;
• procuring a first two-dimensional sheet of bendable material;
• forming an opening through the first two-dimensional sheet of bendable material to serve as an overhead vent opening;
• bending the two-dimensional sheet to form:
• a leading edge of a floor panel;
• a front panel;
• an overhead panel;
• a back panel;
• and
• a trailing edge of the floor panel, all as a first continuous sheet of material;
• procuring a second two-dimensional sheet of material;
• forming openings through the second two-dimensional material to serve as at least one window opening and a door opening;
• procuring a third two-dimensional sheet of material;
• cutting the second two-dimensional sheet of material to have a profile that matches a first side of the first continuous sheet of material;
• thermoplastically welding the second continuous sheet of material to the first side of the first continuous sheet of material;
• cutting the third two-dimensional sheet of material to have a profile that matches a second side of the first continuous sheet of material;
• and
• thermoplastically welding the third continuous sheet of material to the second side of the first continuous sheet of material, thereby forming the envelope.

An envelope for a recreational vehicle, comprising:

• a first continuous sheet of material comprising sets of spaced-apart grooves, with the first continuous sheet of material being folded over at the grooves to form a front wall, an overhead panel, a back wall, and at least a portion of a lower panel;
• a second continuous sheet of material forming a left side panel;
• and
• a third continuous sheet of material forming a right side panel;
• wherein:
• the left side panel is thermoplastically welded onto the first continuous sheet of material on a first side of the first continuous sheet of material;
• the right side panel is thermoplastically welded onto the first continuous sheet of material on a second side of the first continuous sheet of material;
• and wherein:
• each of the first, second, and third continuous sheets of material is fabricated from at least one pliable fiberglass sheet.