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Camper Shell

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Camper Shell

Pop-Top Extended Aero Shell for Toyota Tacome 2WD.

curved edge

Used heat gun and a few layers of PVC to open up the curve in the sanding block to about 3.5" radius.

Top glued on!

This chunk of PVC will be cut up and used to sand the 3" corner radius to mesh the sides up w/ the top.

It was really difficult to get a good seal between the top and the sides. If I were to do it again, I would proabbly lay a strip of wood along the...

Glued and then cut some foam to fit the top of the shell.

took the sides off, once I got everything to fit, and glued the end and by-cab pieces to the sides.

same here.

spherical shape

glue

zig-zags of glue to join pieces with.

All ready for the top cover to be glued down.

Sanding the sides smooth... the top layer will glue smooth with these, and then I'll radius the corners from cab to tail.

Glued another piece of foam along the top of each side piece for double thickness that I could sand through to get the nice corner curve.

First try making flex-lines to wrap the panel around the 3" radius corners going from the top to the sides of the shell.

cutting contour to fit closely behind the cab.

Screw for adjusting side-to-side offset of shell skeleton behind cab.

Started adding bracing

More done...

Construction Details

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