Well after Church I went back to my boat tail build project (must keep priorities in order).
First I took of the boat tail and removed the hatch. Mechanically this is an easy task, 4 bolts and two shocks. Electrically it was a bit more complex. For this I had to find the nearest connection for all the hatch stuff. This turned out to be right behind the license plate. To get at it I had to take apart the plastic inner half of the hatch. Then I had to snake out the wiring. I pulled in two pull cords so I can reattach the wires if I need to down the road.
once that was out I reattached the boat tail and started work.
I started working on the bottom trying to smooth out the connection point from car to boat tail. I do not have a belly pan so this is harder then it should be. From what I can see the old air flow pattern is rather messy from the axle back (next project).
I want to make it flat from the car to the main support piece that attaches to the hitch. So I started adding foam from the top edge of the board till they touched the car.
Then I added two layers from the bottom. It is not even with the support beam but I will fix that when I take it off for fiber-glassing. It will need to be a tapered piece and I will make that when I am not on my back.
exhaust side:
Next I started on the passenger side from where I left off yesterday to tie it in to the bottom.
After that I took a break and watched the 4-7pm football game
When I returned, I started on the drivers side car to boat tail transition. I got that part roughed in from the top to the bottom! I also added 2 feet along that side headed to the end.
I also added the wiring for the new tail lights I bought:
For tomorrow:
1. Smooth out the foam from the car to the frame in prep to fiberglass.
2. Fiberglass from the frame to 4-6" out from the car (no spills on car). I want to do this on top and sides.
3. remove tail and fiberglass edges to get the mounting surfaces smooth and filled in (top and sides).
4. Add 4' of foam to bottom of tail.
5. Add foam to bottom mount area to match the bottom piece to car transition.
After that
Finish the fiber-glassing from car to tail frame (part I have foamed now).
Add sides, back and bottom.
Fiberglass the sides, back and bottom.
Decide on plexi glass size, shape and mount method.
buy plexi glass and fit to tail.
Add lights, license plate and EM sticker
take for test spin
fix any issues that come up.
I might make a floor to match the car floor height
take off plexi glass and start painting outside and in.
reattach plexi glass
Testing
should I fiberglass the inside or not?
will fiberglass set up in 20-30 degree F temps?
Am I overlooking anything?
any ideas, comments or tips?