1st Gen Toyota Tundra Aeroshell Build

[Macskyver]

Originally Posted by aerohead

I vote:
"Top Fabricator" for 2016!
Delicious work!

Thanks man. I appreciate it.

Originally Posted by Xist

Perhaps a 50/50 mix of spar urethane and mineral spirits would prevent that polycarbonate from yellowing.

That might work. My only concern is that it might affect visual acuity through the window. I have plenty of scrap polycarbonate I can run tests on to check. With my design, the windows should be fairly well shaded, so it may be a non issue.

[Macskyver]

After being gone for a week with limited connectivity, I come home to find out that the epoxy for the fiberglass is delayed. How much is uncertain, so I had to cancel it and order two 0.75 gallon kits instead of the single 1.5 gallon kit. It should be here Friday, so I have until then to finish up all the sanding and finish work. It won't really set me back, but I was hoping to fondle some epoxy cans when I got back.. Oh well, such is life.

[Macskyver]

The off time in my last couple of days has been spent behind an orbital sander. I am basically sanding until the camper shell surface is more or less smooth. There are several spots where I didn't have a good glue joint and there is a gap between the strips. I am saving the sawdust from the sander to make some filler paste with the epoxy. After the surface is to my liking, I'll use a punch to set some of the nails that are at the surface a bit deeper. Next step will be swelling the holes shut with water and a heat gun. Then I will make a pass with the putty, filling all the gaps and the nail holes that are still open. After that will be resanding the surface and applying a seal coat of epoxy. This is all a learning experience for me, but I think it will work out fine. Here are some pics of the progress:

[Fastskiguy]

really a cool project to watch evolve, thanks for sharing it!!

[jareddbh]

I am about to go pick up a 2000 Tundra and was planning on doing some minor mods. I love having a camper shell, and this one is spectacular!

Now if only you would make me one too....

[Macskyver]

Originally Posted by Fastskiguy

really a cool project to watch evolve, thanks for sharing it!!

Thanks. I am glad you are enjoying it.

Originally Posted by jareddbh

I am about to go pick up a 2000 Tundra and was planning on doing some minor mods. I love having a camper shell, and this one is spectacular!

Now if only you would make me one too....

Cool. I think you are making a good vehicle choice, although my opinion is slightly biased. I appreciate the props. I am not sure I want to get into the business of making these, but I would be happy to give you information to help you make your own. Maybe when I am done, I'll just prepare a file package with all the CAD drawings, parts lists and order links, etc.

[Macskyver]

I learned a valuable lesson this last weekend. Make sure to wear a respirator when doing a lot of sanding. I have never had issues before, but I must have ingested and inhaled more sawdust than normal. Consequently, I kinda feel like crap and didn't get anything done since last post.

[oldtamiyaphile]

Originally Posted by Macskyver

I learned a valuable lesson this last weekend. Make sure to wear a respirator when doing a lot of sanding. I have never had issues before, but I must have ingested and inhaled more sawdust than normal. Consequently, I kinda feel like crap and didn't get anything done since last post.

Certain kinds of timber can be quite toxic, I used to think wood is natural so it's safe but not so.

[ChazInMT]

Originally Posted by Macskyver

I learned a valuable lesson this last weekend. Make sure to wear a respirator when doing a lot of sanding. I have never had issues before, but I must have ingested and inhaled more sawdust than normal. Consequently, I kinda feel like crap and didn't get anything done since last post.

Likely excuse.....

[freebeard]

I learned a valuable lesson this last weekend... Consequently, I kinda feel like crap and didn't get anything done since last post.

You contradict yourself.

I am not sure I want to get into the business of making these, but I would be happy to give you information to help you make your own. Maybe when I am done, I'll just prepare a file package with all the CAD drawings, parts lists and order links, etc.

That's all you owe anybody; and only because you teased with this thread. Package it up nice and take it to Instructables - DIY How To Make Instructions.

A much bigger audience. Instructables.com Traffic, Demographics and Competitors - Alexa says it's ranked 632 globally and 322 in the USofA.