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Old 08-30-2016, 02:23 PM   #71 (permalink)
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I vote:
"Top Fabricator" for 2016!
Delicious work!
Thanks man. I appreciate it.


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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.

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Old 08-30-2016, 02:32 PM   #72 (permalink)
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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.
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Old 09-04-2016, 01:00 AM   #73 (permalink)
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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:









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Old 09-04-2016, 08:50 AM   #74 (permalink)
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really a cool project to watch evolve, thanks for sharing it!!
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Old 09-05-2016, 06:33 PM   #75 (permalink)
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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....
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Old 09-06-2016, 02:20 PM   #76 (permalink)
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really a cool project to watch evolve, thanks for sharing it!!
Thanks. I am glad you are enjoying it.


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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.
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Old 09-06-2016, 02:32 PM   #77 (permalink)
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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.
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Old 09-06-2016, 07:47 PM   #78 (permalink)
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Quote:
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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.
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Old 09-06-2016, 09:24 PM   #79 (permalink)
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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.....


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Old 09-06-2016, 10:54 PM   #80 (permalink)
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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.

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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.

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aerocap, aeroshell, camper shell

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