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Daox,
I definitely agree, the aluminum needs painted. I am going to wait until I am happy with the performance so that I don’t mess the paint up adjusting it. Luckily since my truck is a base model flat black will help it blend right in. I had seriously considered putting the dam on the bottom of the front bumper, but in addition to the tow hooks I was afraid it would get damaged easier off-road.
Freebeard,
The edge is “semi-finished”, i.e. it isn’t ragged or anything. It cuts pretty clean with a sharp knife. I bought the belt at tractor supply, there was only one size available there, 7” wide 15’ long.
Yes, the bump is there for stiffness reasons, without a significant curve side to side the wind would blow the bottom edge up under the truck.
Good idea, I will add filler pieces to my V1.2 to do list.
I am torn on how to build the camper shell, I go back and forth on making a removable form from cardboard and tape, and later removing it leaving the fiberglass skin. The other option is to make a permanent form out of XPS foam, and fiberglass it on all sides, making a solid structure, similar to a fiberglass surf board. I have the materials to do either. I think the foam would be stronger with less fiberglass, so lighter for equal strength. I think the foam would also be harder to build, but I am not sure. The cardboard/tape/junk form buildup sounds fairly simple.
My plan on the camper shell is a two piece hinged or hatchback design, so part of the roof would be removable for carrying tall objects. I also want windows in the back and sides. All of that adds significant complexity to any design. I have some concept sketches, I will probably upload a design in a few days.
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