@ turbothrush - Yah, I cut two inch wide strips of foam to layer and back up the corner. I would lay glue in zig-zags where pieces of foam overlap and then screw them together to dry...
This glue works pretty good... When joining the pieces, it's difficult to use enough screws to get a good seal, but if I go along w/ my hands and squeeze the glue out along the entire edge of both pieces, they don't separate afterwards. The glue joints also sand well once two pieces of foam board are joined together... When I sand across a glue joint, it tends to ball up before the pieces separate, so the joint stays steady and solid.
Per freebeard, I may not have made the corner foam thick enough... I glued an extra layer of foam on yesterday to add some thicknessm, but I might still need to add some spray foam to the inside before I lay the inside layer of fiberglass. We'll see how rigid it feels after doing the outside layer.
Sooo... good progress today! I cut notches in the x-sections to let me lay the sides in tight:
Can see where the corners are going to need to be radiused from the cab to back:
Both sides affixed w/ some screws:
Sanding flush so that I can glue on a top layer of foam that will be cut through at the corners to make a smooth transition from top to sides and from cab on back... (LOL if this looks like crap when I go at it w/ sandpaper later this week...)
Both sides sanded flush w/ the top profile so I can glue top panels on and then radius the top->side corners... tomorrow or later this week!
the top surface is spherical... so I'm wondering how many pieces I'll need to get the foam to lay smoothly... Ideally, I'd use two pieces, joined along the middle from cab to tailgate. I think the foam has enough flex to do this. Soon we will know!!!
