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ECOfamily Civic and Aero Hitch Box

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ECOfamily Civic and Aero Hitch Box

Construction of Aero Hitch Box

Lid installed for the first time. Almost ready for trip.

lid half painted

cold galvanize compound

corner painted

filler and rivets over corner

fiberglass over corner

corner plug from the outside

corner plug; foam on epoxy putty, from the inside

microsphere filler; try to smooth out shrink wrinkles

Unpleasant sight; the 'clamp' (weights) have fallen over.

Sealing the other side with Loctite PL 3X. Too bad I didn't glass this side first and notice the problem before I destroyed the side that matters...

This resin (polyester?) causes the pink foam to disolve. Nooooo! What I'm supposed to know is that epoxy resin is compatible with the foam. Or that I...

Looks like baggy denim.

Inlay wood into foam for secure attachment.

Getting sanded up.

Use of gap-filled bond for butt-joint at an angle.

Test; strength of gap-filled bond.

Tracing out the top corner piece.

Riveting the top corner piece.

Sealing the top corner lip.

Near end of phase 2; aero hitch box on car, no lid, side view.

Near end of phase 2; aero hitch box on car, no lid, back view.

An example of a good tuck, we need to see an acute angle between the sides of the tuck, without sharp edges on any corner.

Tuck tool welded from 0.5" rod and 1/8" right angle.

This aluminum rib is also the lip that goes around the front, just before I installed it.

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