1st Gen Toyota Tundra Aeroshell Build

[KamperBob]

Macskyver, I'm optimistic about your gains. My 02 is the same model. My record high MPG was 22 with a hard toneau cover. Now I'm using an ARE cap with raised roof for lifestyle not fuel economy optimisation. Just yesterday I got 20. It's comparing apples and oranges yet I see upside to your numbers. Looking forward to your pump reports going forward. Rock on!

[KamperBob]

PS - your aeroshell design shape was so much like the one I designed a few years ago. Sorry, I can't seem to find prior pix I posted (needle-haystack problem) and I can't seem to upload another copy this AM (some security token error -- whatever). Anyway, the basic shape was convex hull. In other words, no concavities to undermine flow attachment. So blend from cab profile to simple arch across back. I like you overhang feature. I really think it's gonna rock!

[freebeard]

Aerocaps converge to a 'type'. I think what distinguishes yours is the CNC-cut parts. I know you said you weren't satisfied [rereading the original posts] but it looks from here to be light years ahead of anything cut by hand.

[Macskyver]

Originally Posted by KamperBob

PS - your aeroshell design shape was so much like the one I designed a few years ago. Sorry, I can't seem to find prior pix I posted (needle-haystack problem) and I can't seem to upload another copy this AM (some security token error -- whatever). Anyway, the basic shape was convex hull. In other words, no concavities to undermine flow attachment. So blend from cab profile to simple arch across back. I like you overhang feature. I really think it's gonna rock!

I sure hope so. At the very least, I should be able to sleep under it without getting wet. That for me will be a win.

Originally Posted by freebeard

Aerocaps converge to a 'type'. I think what distinguishes yours is the CNC-cut parts. I know you said you weren't satisfied [rereading the original posts] but it looks from here to be light years ahead of anything cut by hand.

Yeah, the CNC sure makes things easy sometimes. It would be really awesome if there was some CFD in the mix, but that is outside the scope for this one. The good thing though is that I could probably rework the CAD files to make them parametric, so that with a few variable changes, anyone could prepare designs for whatever sized shell they want. Then anyone could at least print off templates to trace and hand cut if they don't have access to CNC.

[Macskyver]

I apologize for the long lapse in progress, but I finally have an update. Today I finished the first round of sanding the outside surface of the camper shell. Then I made some filler putty with epoxy and saw dust from the orbital sander.



And then I applied the first round of said epoxy filler to the shell, filling the gaps and nail holes.





After this dries, I will sand down the surface and potentially do another round of filler. If it is good enough for government work as they say, I will probably flip the shell over and sand down the inside surface.

[freebeard]

Have you thought about completing the first coat before sanding? The raw wood and the epoxy may not respond to the sandpaper the same and introduce waves.

[Macskyver]

Originally Posted by freebeard

Have you thought about completing the first coat before sanding? The raw wood and the epoxy may not respond to the sandpaper the same and introduce waves.

I don't think it is that big of a problem. The epoxied areas are a bit raised, so I kinda use them like layout fluid and feather them in with the dry areas. The orbital sander works pretty slow, so as long as I am careful, I *shouldn't* make many divots. And there is a natural waviness anyways with the surface due to the wider rib spacing. I guess the final verdict will come very shortly. I should be able to see what the surface will more or less look like after the seal coat.. which is coming very soon.

[Macskyver]

I got the exterior seal coat of epoxy applied. There is quite a bit of blotchiness caused by the previous step. Hopefully it fixes itself as the epoxy dries. There isn't a whole hell of a lot I can do (and that I am willing to do) at this point in the game, so any imperfections I'll chalk up to learning experience and character.

[freebeard]

Squeegee a final layer of epoxy out under a sheet of Mylar, let it cure, and peel off.

[Macskyver]

Over the weekend I got the inside of the shell sanded and epoxied. It was a little dark in the shop when I was applying the epoxy, so I may have to do some touch up in case I missed some spots. Next up is flipping the shell back over and laying down the fiberglass.