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Old 08-03-2012, 09:32 AM   #51 (permalink)
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Looks good to me too.
One question: Are you planning on putting in windows so you can see through it, or are you just really good with your side mirrors?

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Old 08-03-2012, 08:50 PM   #52 (permalink)
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Thanks,

No plans for a rear window, Im pretty good with my side mirrors as Im used to driving without my center mirror (out of the previous 4 cars Ive driven on a daily basis Ive only been able to see out the rear window of one of them), i do need some better side mirrors though, these ones are huge but not at all "wide angle" so they don't show me much (bad for aero and vision!).

I am considering some small side windows though as i will be using the cap for accommodation while camping and its going to be pretty dark in there otherwise.

In other news i just filled up for my best tank ever! Still only a measly 7.76mpg but it seems that keeping the vacuum steady while cruising and keeping it above 10inhg while accelerating and going up hills seems to be working, it has also kept my speed down slightly (averaging ~90kmh instead of 100kmh on the open road). Hopefully now with the aerocap underway i will keep beating my records!

Last edited by bobo333; 08-03-2012 at 08:59 PM..
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Old 08-03-2012, 10:05 PM   #53 (permalink)
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Looks good, I was troubled when I first saw this cause it normally needs to be taler in back, but with the long bed and having a raised rear end, it does look like you're on the right track here.

Last edited by ChazInMT; 08-03-2012 at 10:13 PM..
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Old 08-04-2012, 04:40 AM   #54 (permalink)
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Hi guys,

Did a lil more work today, firstly i glued and screwed a piece of 3mm mdf onto the front panel to seal it up, then put it on the back of the cab to double check i got all the angles right:


Then i screwed the 2 side panels on so i could measure the lengths of the pine braces that will be going across the top:




I need to get more pine tommorow before i go any further.

Thanks for looking
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Old 08-05-2012, 09:35 AM   #55 (permalink)
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Am enjoying this. Good to see that vehicle electrical was the first task . . frustrating that others may spend thousands before getting to this most important system.

The FF/RR "rake" on that truck is exaggerated . . too high in RR and FF looks as though it were dropped, as well. I'd want more the factory rake to work from. Handling, braking, etc, will be better (not to mention wear on various items). I'm thinking that an FSM or on one of the FORD truck enthusiast sites someone may have the range of factory high/low limits for the body/suspension.
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Old 08-05-2012, 11:53 AM   #56 (permalink)
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Yeah the rake is a bit ridicules, i think it has heavier duty springs in the rear too as it only dropped an inch the other day with well over 500kg in the back, eventually i want to get it sitting nice and low with more street orientated wheels and tires on it but i don't have the money for new suspension at the moment.

Tomorrow Im going to get some more pine for the Aerocap as well as some primer/sealer and paint.

Last edited by bobo333; 08-05-2012 at 02:05 PM..
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Old 08-06-2012, 09:28 AM   #57 (permalink)
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Hi guys,

I got some more pine today to continue the aerocap, first i measured out the shape of the tray and put some screws into my big sheet of chipboard to use as a jig and make sure everything is square, then i assembled the front and side panels the same as i did the other day before filling in between them with pine:


Then i took a small wedge out of the legs on the rails on my bed and bent them in to the same angle as the sides of the cab:


then the moment of truth came, i slid the aerocap on (just! its kinda heavy lol, once I've got the top panel on it will definitely be a 2 man job)


thanks to my jig it all fit perfectly!






i then drilled holes into the rails and used big heavy duty screws to secure the cap onto the rails:




I can shake the whole truck from the cap and it doesn't move at all so i think it is strong enough!

Now i need to get the top on an cut to shape before disassembling it all again to seal and paint it, i will then put it all back together and possibly fiber glass over the corners, then smooth everything out, make it permanently 1 piece and give it the final coat of paint.

Thanks for looking
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Old 08-06-2012, 11:15 PM   #58 (permalink)
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If you are capable of glassing, why not use the form you just made as a positive, then make a negative mold and make another from fiberglass? It'll be much lighter and stronger.
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Old 08-07-2012, 04:41 AM   #59 (permalink)
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Hi guys

Quote:
If you are capable of glassing, why not use the form you just made as a positive, then make a negative mold and make another from fiberglass? It'll be much lighter and stronger.
The main strength of doing it this way is the price, so far it has cost me well under $50 in materials, if i made a mold then redid it in fiberglass id be using hundreds of dollars of fiberglass materials (mat/resin etc), this one is plenty strong enough (i was standing on it just before) and doesnt really need to be light due to the weight capacity of the truck.

Having said that i may redo it later on down the track, possibly in fiberglass, possibly in sheet metal, to get a better finish and make it easyer to put on/remove with just 1 person.

Here is todays work:

First i put my big sheet of chipboard on top and got it straight and centered, then i ran the jigsaw down each side to make it the same shape as the side panels:


then i measured the back and cut it to the same length as the bed, and screwed the top on:


just needs a bunch of sanding and sealing, i may still fiberglass the corners for a perfect seal but il see how it goes




i was gonna get paint today too but i ran out of time so il have to get it tommorow

Thanks for looking
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Old 08-07-2012, 12:15 PM   #60 (permalink)
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Wow that looks absolutely fantastic! Awesome work. Looking forward to seeing it painted!
EDIT: Are you thinking about rear wheel skirts too?

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Last edited by Flakbadger; 08-07-2012 at 12:22 PM..
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