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Old 10-16-2016, 12:13 AM   #9 (permalink)
Cowcharge
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Join Date: Oct 2016
Location: U.S.
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Added the rear bulkheads to the side boxes, 3/4" ply. I chose the curve to keep some usable space in the back of the side boxes. Nothing is attached to the truck at this point, nor are the walls attached to the front bulkhead. The hardest design part so far is trying to figure out how to shape the side box doors. I bought a sheet of coroplast to make templates, but I need to make the door frames, and several molding stations, in order to get the proper compound curve as the doors go from almost vertical up front to almost horizontal in the back. I also need to make the doors come out sideways before swinging up to keep them from fouling on the lid, so I'm planning to use "U"-shaped hinges like on a car trunk lid, rather than just hinging them to the top of the boxes. The box tops are cut at an angle on the outside edges, as will be the door and lid edges, so they will wedge-fit together like the lid on a jack o'lantern, with weatherstripping filling the gap. The plan is to laminate three layers of kerfed 1/4" birch ply to make strong, light doors that will line up with the cab sides and the side edges of the lid.


Last edited by Cowcharge; 10-16-2016 at 12:29 AM..
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