1gen Neon Kammback/Hatch conversion

[MetroMPG]

Update on this project, NoD?

[NoD~]

REALLY wish I've found the time to work on this. Summer has been rough. I really haven't touched it since the last update, sadly. It's still on mind, though. Hoping winter will offer more time to get crackin on this project!

[NoD~]

Alright, back to work! Winter is going away and I've been doing some highway trips. The whole, I'm thinking "Man, I'd save a few bux if I had that damn shell done already..."

One of the hold-ups was how to do a new rear view setup. I was going to do some acrylic window, which added further complexity to the design. Because I want to take out the original factory window to save some weight, I need something that can go on right away. Not that acrylic is gonna be that big of a deal, but I wanted simpler, if possible.

So, I did a bit of Amazon shopping. I found a decent small camera and LCD Monitor. I'll be replacing the rear view with that.

This also gives me real estate for some solar paneling. Also, keeping the rigid foam, more insulation from the hot summer days and cold winter nights.

So that should be here shortly, and I'll do some testing to make sure it's gonna do what I think I want it to.

Next up: Trying to get the sides done. It's a lot of work doing layer after layer, so I think I'm just gonna "fill the gaps" with expanding foam. This should be good enough until a layer of glass goes over the top.

Still trying to find where I can get some epoxy based resin to keep from eating the foam. Is there anything more common that can be used, like polyurethane floor covering or some sort of glue? Doubt it, but worth asking.

[MetroMPG]

Epoxy resin: I got mine at a marine supply shop. (They'll also sell polyester - check the labels.)

[jedi_sol]

Originally Posted by NoD~

Still trying to find where I can get some epoxy based resin to keep from eating the foam. Is there anything more common that can be used, like polyurethane floor covering or some sort of glue? Doubt it, but worth asking.

Home Depot fiberglass resin does not eat thru foam (in my experience at least). Its really stinky...but it cures in 15minutes, so it might not be very useful in larger applications like your situation.

[freebeard]

What did you think of 2000neon's solution:


The sides are important to the aerodynamic performance. You need to get the right taper and tumblehome. A lot of rear visibility will go away, three cameras would be better than one.

Are you still planning on making it a liftback? Chevy Nova did that in 1974 as an option to their standard notchback.



You could research what they did to stiffen the body.

[NoD~]

I think the design/idea is great! Though, I want a few things different...

First, I want a solid and permanent surface. The foam/fiberglass should do this nicely. Secondly, I literally never use my trunk... so no need for the hinged system he has in place (The trunk is actually just a pinned down skin right now anyways). Finally, I want to reduce weight, since the vast majority of my driving is city, where weight matters. Therefor, ridding of the rear windshield is high on my "to do" list.

Finally, my build is going to give me 1 more thing... A "trailer hitch Boat Tail". Not to say 2000neon's build won't do it, but mine will be an easier fitment. Basically, for road trips and such, I'm planning on making a quick extension that will attach to my small trailer hitch. This should make any longer trips I do help save a bit. Of course, this is much later... I gotta get the kammback done first!

Otherwise, 2000's build is absolutely awesome and practical! Just not what I have planned for my build.

[freebeard]

(The trunk is actually just a pinned down skin right now anyways)

I'd noticed the pins and tape.

Fiberglass will need a lot of finish work to look presentable, unless you make a female form to lay it into. And you'll need to wear a respirator. Have you considered PolyMetal? Get a 3x5ft piece, roll it to shape and roll the edge to stiffen it and you're done! It probably would be lighter than the foam/fiberglass option.

Are you going to cut out the bulkhead between the back seat and trunk space?

The trailer hitch 'tail will need at least 3 points of attachment.

[Dubbio]

Any further progress?

[NoD~]

Well, I Got me an Insight... so that means I could FINALLY put some dedicated time into the red Neon!

We are going on a road trip shortly, so right after getting the Insight, I was able to get this done...




It didn't turn out perfect, but it should work for now. Here's the steps...

I Put on a cargo carrier on the back. Had a friend weld a bit of angle on it, as it seems to sag down a degree or two. Should keep from scraping (and hasn't yet!)


Coroplast from bumper to all under the carrier. Made a new rear end with all LED lighting.



Made some framwork from 3/4" plywood.


Last time I took this same trip about this same time of year, I pulled in 57-59 MPG. I'm hoping to see 60 this go.

2 big mistakes I made (and I blame time frame... mostly):
-The shape at the top of the removable back window is too side. Looking down the side of the car, I can clearly see it sticking out a bit. Should have cut that a little more.
-The window I used was some clear vinyl table cloth from Jo Anns. It is blurry and not stetched well. May try to get it fixed before we go.

Wish me luck! 1000 miles about to go down...