The Amocat- 2005 Tacoma

[freebeard]

Cut at an angle, so when the section moves in, it tightens the gap from the saw cut.

[elhigh]

If you don't need to seal the gap between the cap and cab, you might want to consider not doing it.

I know, aerodynamically an uninterrupted skin is best. But I've been driving my truck for over 25 years now and it's had a cap on for all but maybe a year of that. The front of my cap has no window but a gap filler to close up the space between the cap and cab. Over the years, it has worn right through the paint and primer and there is a thin ring of bare steel visible all around the rear window when I take the cap off.

Just a thought.

[freebeard]

Or you could just put a few extra coats of paint on, with some air-dry time before the seal is implemented.

[aardvarcus]

Elhigh,
I don't like the sound of wearing through the paint! I would like to make it at least semi-waterproof so I would like some sort of gap filler. What kind of material did you use for a gap filler? Maybe something soft like sheet rubber or silicone wouldn't damage the paint, or is that what you used? I also thought of attaching something to the truck with 3M double sided tape to have the seal set against, which would be removed if needed.

In other news, I ordered some more fiberglass epoxy, just waiting for it to show up so I can get back to work.

[aardvarcus]

The fiberglass epoxy showed up, but I had been too busy to use it. Finally yesterday I carved out an hour or so and finished the first layer of fiberglass on top of the shell. I ordered a small digital kitchen scale, which worked out really good for mixing the epoxy at the right ratio, way easier than using measuring cups.

My plan is to flip the shell over and do one layer on the underside. Then I will flip the shell back upright and do another two or so layers on the topside. Then the shell should be ready for surface prep and paint.

[aardvarcus]

Insomnia helped facilitate my latest progress. Anyway I put a layer on the bottom of the entire shell, and then using the leftover epoxy from my last batch doubled up a few of the areas that had thinner foam around the window openings. Next I am going to flip it back upright and add a few layers to the topside.

[aerohead]

There's little risk that she'll explode on you now.You would not have wanted to go 'there.'

[aardvarcus]

Aerohead,
Yeah I don’t need any explosions or implosions for that matter. It is pretty solid, but not quite goat proof.

Well I finally had time to flip it back upright and do another layer on the top of the shell, and then promptly ran out of epoxy again. So I guess I am finished with epoxying. I let it dry and did a test fit and got some pictures. Now it is just time for trimming, sanding, bondo, sanding, primer, paint, and window install. Then it can get a test drive and I can start recording some numbers. Anyway, the pictures.

[aerohead]

Sweet! She looks like money in the bank.'pretty sure you'll like the handling,ride,and less frequent stops at the gas pump.Highway driving anyway.

[rumdog]

Cool man, looks good. I like the rounded corners and i think the air will too. It looks lightweight.