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Old 08-02-2009, 11:53 PM   #12 (permalink)
Bicycle Bob
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Join Date: May 2008
Location: N. Saskatchewan, CA
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Appliance White - '93 Geo Metro 4-Dr. Auto
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"Plexiglas on top" ?? You already have a kammback with attached flow over the rear window. The thing to do is to just continue the same line to a smaller terminus. To keep the signal lights visible from both sides, you'd probably want the extension all clear anyway. It isn't easy to do that with light weight and neat appearance. It might be better to go all opaque, and put trailer lights on the tailcone.
The design could work well with just flat-wrapped sheet stock and no compound curves. If you don't like Coroplast, sheet PVC or coloured polycarbonate would probably work well at a reasonably light gauge. Craig Vetter is happy with his thin solid stock, but I can't remember the compound.

To get a really nice appearance, a mold is probably best. It could be filled with fiberglass or vacuum-formed thermoplastic, and then reinforced with "hat sections" bonded to the inside. Those can also be used if sheet stock is just held in a simple jig to give it the right shape. The can fan out from a metal or 'glass tube that goes in the hitch receiver. You might want a long tongue that goes right through the hitch receiver to make mounting easier, with an extension handle for tightening.
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