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Old 04-22-2015, 07:48 AM   #53 (permalink)
aardvarcus
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Join Date: Apr 2012
Location: Evensville, TN
Posts: 676

Deep Blue - '94 GMC Suburban K2500 SLE
90 day: 23.75 mpg (US)

Griffin (T4R) - '99 Toyota 4Runner SR5
90 day: 25.43 mpg (US)
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More progress, I laid some more fiberglass on the top to side radius transitions from the back side, also included some strips of XPS foam to create a box beam out of the fiberglass, which stiffened the assembly up substantially. I did some bondo work (material not person) on top of the fiberglass. Some of the areas needed built up a bit. I clamped an aluminum piece to the two sides to “simulate” the lexan window edge, and then built up material so that the shell will have a lip for the window to make it flush. I did some rough sawing and sanding, and then had to add some more material to some of the low spots. Hopefully some more light sanding and I can start priming the shell. Finally on the downhill stretch. And of course a couple pictures of the bondo progress.

And what would be one project finishing up without two more underway. I finished the design of my electric fan controller, and ordered most of the parts. I will get pictures and do a detailed write up when finished.

I also am doing some serious head scratching on the Tacoma underbody, so I took some pictures of the underbelly and did a rough sketch of the layout, very roughly to scale. I attached it here in case others find it useful. I will post a design and ask for feedback soon.
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Last edited by aardvarcus; 04-22-2015 at 12:29 PM.. Reason: Forgot to upload pictures.
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