Update with current photos:
Next steps are:
* Build back door for shell.
* Build lift Mechanism and canvas sides.
* 2nd layer of fiberglass on outside
* Finish sanding, primer, and paint
* Misc stuff.
-------------- First Post Below ---------------
I Had a shell on my truck a few years ago, but it cost me ~4mpg, per the scanguage. I'd really like to have something to sleep under on trips and stuff, so I'm working up designs for a pop-top aero camper shell.
Design Criteria Are:
- Lightweight and Aerodynamic - Improving my MPG rather than hurting it!
- Extend to end of lowered tailgate so I (6'2") have room to stretch out under it
- Have enough room for me to have a raised floor to hide snowboards/other gear while still having room to sit up and move around comfortably (about a 3' lifit)
- Follow the body lines of the truck
- Simple and convenient to use
I'm planning on using fiberglass over 1/2" pink foam construction. In the CAD drawing below, I'm working on the cross-sections that I'll lay the foam over to get the shape right. I'm using a single radius curve for the shape right now. Given the non-agressive shape I'm using, do I need to think about the complex curves used in the aero template?
CAD drawing (will keep this updated) is here:
https://docs.google.com/open?id=0B4K...0thT2F5VDV6WUE
If you use chrome browser and google docs, you can install the "AutoCAD WS" addon and view/edit the drawing in the browser. Pretty cool stuff.
