One of my local friends and the welder that helped me with all the truck frame and suspension mods is telling me i have to follow the template now. This guy is not an ecomodder, but he sees the beauty.
I will feel the pain
We can build the radius sections with either:
Strips of 2" foam faired with epoxy putty like this.
Bateau2.com - Technical support for builders
Or we can try layering a couple of 1" thick panels. I doubt we can bend the 2" that tight.
I did research the foam available. The standard is square edge, at 25 PSI and 1.5 lb/sq.ft. I can get it in many thicknesses.
There is high strength 40,60, and 100 PSI. It also has double the flexural strength.
It is typically used under concrete runways and road sections.
The 40 and 60 weigh in at 2.2 lb/sq.ft. and the 100 is 3.0 lb/.sq.ft.
I think I'll build a floor sandwich with light ply and the 60 or 100. it is incredibly strong, and all of it is rated at R5 per inch. The high strength is only available in 2" and 3" thickness.
The design has morphed again to utilize the space that is wasted behind the cab of the truck, and shortened by 4' at the back.
I'll build an aeroshell as proof of concept, to perfect the lamination, foam bending, and final layup techniques.
This plastic top sheet layup is very promising. I'll be trying that out shortly.
A new Technique for Epoxy-Glass