Testing aeroshell/boat tail For the Dodge

[skyking]

Later today, I am starting a testing aeroshell with integrated boat tail for my truck. No scangauge, I drive it few miles a year, so i am cutting right to the chase. I call it A-M-A testing
I am picking up the template at station 10, a point with 3.5° slope. I figure that will get me down faster, and is not a huge departure from <Shatner voice> the ...beauty , that is....the, template </Shatner voice>.
Length is still not a concrete number. It is somewhere around a total length of 12'.
I welded up my headache rack yesterday, and I will hinge this whole thing off it IF/when I build the permanent one. this one will probably be fixed for testing.
I have some nice big sheets of virgin cardboard to skin it with. A ton of scrap lumber, fasteners, some old gate hinges, etc.
I can borrow the tail lights and a pigtail for the lights.
Why now? I have a 320 mile 55~60 MPH round trip across the mountains to do Monday/Tuesday, and maybe a 450 mile 70 MPH freeway run in the middle of that, fuel paid. These opportunities just do not fall off the trees.

[slowmover]

Fuel paid, no kidding!! Looking forward to it.

[JRMichler]

Photos. We need photos.

[skyking]

Right now, it sits in my noggin. I have to build a linux server first, that is the reason for the trip.
I hope to have some framework constructed today that will be picture worthy.

[ECONORAM]

Looking forward to the progress. opcorn:

[KamperBob]

I don't recall your Dodge. If it's covered on another thread, a cross link would be peachy.

Rock on!

[Rokeby]

Skyking,

Will fuel be paid for based on:
a. a pre-established per mile rate, (Ka-ching!)
b. or based on gas pump receipts? (Why bother?)

[skyking]

Originally Posted by KamperBob

I don't recall your Dodge. If it's covered on another thread, a cross link would be peachy.

Rock on!

It is Woody, right there below my avatar.
The only other thread:
http://ecomodder.com/forum/showthrea...sel-21857.html

Skyking,

Will fuel be paid for based on:
a. a pre-established per mile rate, (Ka-ching!)
b. or based on gas pump receipts? (Why bother?)

Based on: the 60 MPH portion is for a job I get paid to do, namely set up a replacement server; the 450 mile 70 MPH part is tentative and more informal
Took me a while to get to the truck. I finished up the rack and need to paint it this morning, did not have hinges, need supplies.
Good news? I have help coming.

[skyking]

Help did not materialize, but I moved the schedule back a day. Design by noggin has morphed several times today. Will return with pics when the skeeters start eating me up

[skyking]

I wanted to use the template as closely as possible, so I designed a shell with longitudinal ribs. Now to get the shape right
I started by laying a sheet of plywood on the floor and tracing it. There is very little else you can find that is more true and square than a sheet of plywood.

I moved it 4 feet, so I could get a 12' grid drawn.

I moved it a couple more times, ending up with a 6' x 12' grid, on 2' spacing.
I hope to build a tail for the truck and thought I could use the length.
Now I could arrange the sheet of plywood to minimize waste.

Using a printed image of the template, resized to suit my truck, I scaled it to get dimensions at stations, and transfer that onto the sheet. I pulled a tape and also made station lines on the angled plywood.
Now I have marks on the plywood that are 2' apart. I want to draw a smooth curve through these points. I have a fiberglass rod for network wiring, but a 10' stick of 1/2" CPVC pipe will work as well.
I started by clamping the rod at one end over a mark, then bent it across the next and the next, taking time to smooth the curve.






I cut the first one out very carefully with the sabre saw. Since the cut is so close to a rip with the grain, the saw wandered pretty badly.
I got a decent looking curve after a couple of attempts, then used that as a guide. Once again, the sabre saw would not track well.
I ended up setting my cordless circular saw to just barely go through the 3/8" ply, and used it instead.


4 finished curves.


I painted the headache rack with something close off the bomb can shelf.






Installed and bolted in solid.



I clamped a piece of 3/8" ply to the rack, and transfer marked it with a straight edge laid on the cab, and cut it out. It has 1/2" margin for the skin and construction method.


My box lids are one of the challenges. I have to make a door in each side of the shell so I can get into the boxes.

This also makes a big hole in the structure I have to work around.