Fuel Economy, Hypermiling, EcoModding News and Forum - EcoModder.com - View Single Post - Design help needed: Custom aero camper top

huntersirg · 02-21-2015, 06:43 PM

Thanks Aerohead for the ideas, I actually have a boat that would almost work but would still require someone over 5"6 (I'm 5"8) to hunch over a bit. Also the thing is quite heavy and way to thick for to highest point on the van.

How about the corners on the sides would a sharp edge cut better or a smooth wide rounded side like most tops I see be more efficient?

Got a couple ways to make it that I'm pondering.

One would be to make the side templates out of 3/4 inch ply and add 2x3 cross beams then lay and curve 1/4 ply to shape fiberglassing over the out side and coating the inside with epoxy.

Or make the whole top out of 1/4 using a boat construction known as stitch and glue which would be less sturdy but much lighter. Coule be attached with sheet metal screws and the strongest body adhesive I can find. Then for extra security I can add some drip rail clamps that pull everything tight.

I will also need to have racks on top for paddleboards and gear but these could be removed for long distance trips.

Thanks again!

02-21-2015, 06:43 PM	#4 (permalink)
huntersirg EcoModding Lurker Join Date: Jan 2012 Location: Florida Posts: 4 Thanks: 0 Thanked 0 Times in 0 Posts	Thanks Aerohead for the ideas, I actually have a boat that would almost work but would still require someone over 5"6 (I'm 5"8) to hunch over a bit. Also the thing is quite heavy and way to thick for to highest point on the van. How about the corners on the sides would a sharp edge cut better or a smooth wide rounded side like most tops I see be more efficient? Got a couple ways to make it that I'm pondering. One would be to make the side templates out of 3/4 inch ply and add 2x3 cross beams then lay and curve 1/4 ply to shape fiberglassing over the out side and coating the inside with epoxy. Or make the whole top out of 1/4 using a boat construction known as stitch and glue which would be less sturdy but much lighter. Coule be attached with sheet metal screws and the strongest body adhesive I can find. Then for extra security I can add some drip rail clamps that pull everything tight. I will also need to have racks on top for paddleboards and gear but these could be removed for long distance trips. Thanks again!