Another truck aero cap idea...

[aerohead]

Oh yeah!!!!!!!!!!!!!!!!!!
Tropos-fear-ic!

[BamZipPow]

I have a crazy idea to form and shape the rear camera mast with wax! It should be rather inexpensive and and easy medium to work with. I should be able to begin the transformation when I git back home from my current trip in Arkansas.

[BamZipPow]

Been doing some more calculations on the next rebuild of the aero cap. I'm looking into using these quick release fasteners fer the front access doors and git away from the locking pins that I initially started with. The access doors will be constructed from aluminum sheet and reinforced with angle strips. It should make deploying the cab cover much easier!
https://www.ebay.com/itm/4-Universal...k/233178980141

I've already upgraded the upper gap cover with slotted angle and will eventually replace the rest of the 2x3 wood supports with the same slotted angle. The aero cap panels will be shaped polystyrene foam and covered with aluminum flashing adhered with Glidden Gripper primer. The panels will be bolted to the slotted angle to secure them from flying away.

[kach22i]

Originally Posted by BamZipPow

I'm looking into using these quick release fasteners fer the front access doors and git away from the locking pins that I initially started with..................

..............will eventually replace the rest of the 2x3 wood supports with the same slotted angle......

An interesting product, could maybe replace both locking pins and push button automotive fasteners in some applications.

4× Universal Push Button Quick Release Hood Bonnet Lock Clip Latch Bumper Black
https://www.ebay.com/itm/4-Universal...k/233178980141



In what respect is angle iron better than 2x3's?

Weight?

Strength?

[freebeard]

In what respect is angle iron better than 2x3's?

It's not wood.

[kach22i]

Originally Posted by freebeard

It's not wood.

Angle iron (soft steel) is kind of heavy for it's strength, and it bends or twist quite a bit compared to wood in my opinion.

Rust Vs Rot?

I'm a big fan of aluminum and even composites in certain situations.

I used angle iron daily 40 years ago while helping install garage door operators. We had a special crimp/pinch cutter with lever arm that I loved to use.

I have fond memories of angle iron as a fast material/tool in the right situation.

Lock washers or Loctite?

Or zip-ties?

[freebeard]

Perhaps BZP can say how much wood he's replaced all ready.

I think it's Okay for roof racks and woody bodies, but underneath a vehicle the environment is not so kind. Wood absorbs water, and it crushes under the fasteners and gets sloppy.

Agreed aluminum is lighter. For sheeting, I like Polymetal and 1/8" ABS sheet.

[BamZipPow]

Originally Posted by kach22i

In what respect is angle iron better than 2x3's?

Weight?

Strength?

Originally Posted by kach22i

Angle iron (soft steel) is kind of heavy for it's strength, and it bends or twist quite a bit compared to wood in my opinion.

Rust Vs Rot?

I'm a big fan of aluminum and even composites in certain situations.

I used angle iron daily 40 years ago while helping install garage door operators. We had a special crimp/pinch cutter with lever arm that I loved to use.

I have fond memories of angle iron as a fast material/tool in the right situation.

Lock washers or Loctite?

Or zip-ties?

Keep in mind that my aero cap is basically a frame with panels that bolt on. The 2x3s have served their purpose over the past 8-9 years. The main 2x3 rails are starting to rot out as well as warping and I need to move on to a more durable material since it's been established that my aero cap build design will fit my needs. The slotted angle iron is readily available and I should be able to easily take the aero cap apart should the need arise. I can build the new frame with the slotted angle and then bolt on my exterior panels to the frame from the inside. The panels will have flat bars with threaded holes embedded into the panels so it will be able to hold the panels in place without any fasteners on the outside of the panels. Currently, the panels are screwed onto the 2x3 wood rails from the outside at multiple points.

I don't think there is a major concern about the frame flexing or twisting in the areas that I will be using it at. I will most likely use other materials like rectangular tubing or gussets to bolster areas needing extra support. The slotted angle I'm looking at is 14 gauge and should be beefy enough fer where I'm using it at. They will be bolted together with 1/4" bolts, flat washers, and Nylok nuts.

The extruded polystyrene (EPS) foam panels will be fastened flat against the slotted angle from the inside. This will allow me to shape the exterior of the foam panels to a compound curve where it needs to be and then use strips of aluminum flashing attached with Glidden Gripper primer to help protect the EPS foam from UV degradation. This should allow me the capability to change out the panels as I need to test various options and configurations or easily disassemble the aero cap fer transport of bigger items. If I need security, I could always bolt on more durable material like aluminum sheet panels in place of the EPS foam panels later on or even have something like Line-X sprayed on top of the aluminum flashing.

[BamZipPow]

Originally Posted by freebeard

Perhaps BZP can say how much wood he's replaced all ready.

I think it's Okay for roof racks and woody bodies, but underneath a vehicle the environment is not so kind. Wood absorbs water, and it crushes under the fasteners and gets sloppy.

Agreed aluminum is lighter. For sheeting, I like Polymetal and 1/8" ABS sheet.

Since most of my projects have started out with wood, it only made sense to move to a more durable material once I was able to prove my design was going to work fer my needs. The first place to replace the wood parts was with the supports fer my dropped belly pan. Now it's time to move on to the aero cap. Eventually, Dark Aero will git the metal treatment as well!

I would love to afford everything in aluminum but my design isn't at a final stage to move to that just yet. Polymetal is still out of my price range compared to the other lower cost materials available in my area.

[BamZipPow]

A quick fitment test. Hopefully, the fasteners will hold up over time and vibrations.