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So yesterday I restarted building a complete aeroshell bedcover for the Tacoma, to replace the half bedcover I have been using for a while. As for why…. good question. Really looking to get some dry storage in the bed of the truck the half shell does not offer. I had already made up the custom curved main foam piece a long time ago when I was going back and forth on the original bedcover project. I took that main piece and foam-glued some other scrap extruded polystyrene pieces together to make a slightly oversized foam hunk to carve the final contoured shape out of. Once I get it contoured, I will put fiberglass over the foam to make a lightweight but strong shell. The design will have two side windows and one opening window in the back, which I have not yet cut out. Here are some photos of the rough foam block.
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