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Old 08-16-2011, 11:26 AM   #11 (permalink)
skyking
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Join Date: Apr 2011
Location: Tacoma WA
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Woody - '96 Dodge Ram 2500 SLT
Team Cummins
90 day: 23.82 mpg (US)

Avion and Woody - '96 Dodge/Avion Ram 2500/5th wheel combo
90 day: 15.1 mpg (US)

TD eye eye eye - '03 Volkswagen Beetle GLS
90 day: 49.05 mpg (US)

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think of the foam as a form or shape. It has a certain rigidity, but the glass and epoxy are what is strong. Lay up the outside of your foam shape with a single layer of cloth and epoxy, add filler coats so you can sand safely, and smooth it out. You need those filler coats so you don't sand into the glass. It takes out all the strength if you do that.
Now, turn it over and glass the inside. At this point you can remove the wood framing, if your design allows for that. The foam and glass inside and out are plenty strong.
The inside has no "smooth" requirements. You can imbed short steel straps under several layers of glass and epoxy, and use those to drill up for mounting screws.
If you are moving your tail lights or otherwise covering them up with this boat tail, you can use that pocket in the car for attaching those mounting straps.
That takes care of the midpoint attachment.
Some people have installed inexpensive bumper hitches to take most of the mounting duty. Put the hitch on the car and make a bracket to fit between it and your tail.

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2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
Custom cab, auto, 3.55 gears
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