1st Gen Toyota Tundra Aeroshell Build

[Macskyver]

Originally Posted by Jeddy53824

That is gorgeous.

Thanks.

Originally Posted by freebeard

You pour the resin, squeegee over the top of the Mylar and let the resin cure before you peel the Mylar off.

I've done the same thing with paint stripper and 4mm polyethylene. The stripper melts the paint to the poly and when you peel it off the paint comes too. It's much tidier.

How well does that work in practice on large surfaces? I imagine you can't easily get mylar in a large enough single sheet to do a camper shell. Also, how thick are you doing the epoxy? Is it still the multiple thin layers or a single thick layer?

[freebeard]

I'll defer to skyking since he's actually done it.

Done right the gloss finish of the Mylar transfers to the resin. skyking talked about butting the pieces and sanding down the resulting ridge. I think if you lap the pieces, the resulting difference in height would only be the thickness of the sheet Mylar.

[Macskyver]

This last weekend I finished up doing the exterior varnish. I was originally going to do 10ish coats, but after reading the varnish technical data sheet a little closer, I found that only 2-3 coats over epoxy is enough for proper protection. After all was said and done, I ended up with 6 coats over the exterior with 4 coats under the eaves. This should be more than enough, and I can always add more at a later date.









Next up will be the installation of the windows. I still have a few aluminum pieces to design and cut out for this, but that shouldn't take too long.

[skyking]

Beautiful!

[freebeard]

Wouldn't brass be a better match for the finish?

And pinstripes and gold-leaf lettering?

[Macskyver]

Originally Posted by freebeard

Wouldn't brass be a better match for the finish?

And pinstripes and gold-leaf lettering?

Oooh.. now you're talking! Maybe I'll have to anodize the aluminum pieces a brass color when I am done.

[Macskyver]

Last night I assembled the front window/slider. Here are some pics of the progress:

[ctmaybury@yahoo.com]

Beautiful work. Make sure you can easily open and close the door from the inside. I would leave the latch open so I could push the topper open from the inside. Be real carfull with the heater selection so you don't poison yourself with co on those cold nights.

[skyking]

Originally Posted by Macskyver

Thanks.




How well does that work in practice on large surfaces? I imagine you can't easily get mylar in a large enough single sheet to do a camper shell. Also, how thick are you doing the epoxy? Is it still the multiple thin layers or a single thick layer?

Here is a link to the thread where we discussed it.

http://ecomodder.com/forum/showthrea...yup-20811.html
The mylar would never conform to a compound shape. It is rigid in-plane so you can bend radii and such, but curving in that other direction won't work.
I put down a layer of cloth, wet it, put the mylar on and squeegee over the top of the mylar. This removes huge quantities of resin out the edge, and results in the lightest possible smooth layup. I mean, glass-smooth, and as little resin as possible. The mylar acts to compact the cloth.
It is a poor man's vacuum bagging setup.
I plan on using it whenever I can.

[Macskyver]

Originally Posted by ctmaybury@yahoo.com

Beautiful work. Make sure you can easily open and close the door from the inside. I would leave the latch open so I could push the topper open from the inside. Be real carfull with the heater selection so you don't poison yourself with co on those cold nights.

Thanks. I am making it so the outside is only latchable/lockable with keys. The rear window will be held open and closed with and air spring and there will be some sort of way to lock it from the inside. I will also probably keep my truck cab rear slider unlatched so I can crawl through that window if needed.

I am not planning on having any sort of heater in it. I've camped plenty in below freezing temperatures without one. It will just mean I will have more incentive to bring a "hot" woman along with me. I do have vents built in though to make sure I don't asphyxiate.

Originally Posted by skyking

Here is a link to the thread where we discussed it.

http://ecomodder.com/forum/showthrea...yup-20811.html
The mylar would never conform to a compound shape. It is rigid in-plane so you can bend radii and such, but curving in that other direction won't work.
I put down a layer of cloth, wet it, put the mylar on and squeegee over the top of the mylar. This removes huge quantities of resin out the edge, and results in the lightest possible smooth layup. I mean, glass-smooth, and as little resin as possible. The mylar acts to compact the cloth.
It is a poor man's vacuum bagging setup.
I plan on using it whenever I can.

Thanks for the link. That is some good information. I will have to try that technique sometime.