Project Extended Pop-Top Aerodynamic Camper Shell ('99 Tacoma) - Page 15 - Fuel Economy, Hypermiling, EcoModding News and Forum

JRP3 · 10-29-2012, 09:39 AM

I'm not talking about a thick layer of epoxy, just not absorbing some of the excess the way you described, to have a "wetter" layup. Epoxy is pretty flexible, much more so than polyester resin.

Chris D. · 11-04-2012, 09:04 PM

I think I would have ditched the tailgate for weight savings since you really can't use it..

ChazInMT · 11-05-2012, 03:48 AM

I can think of 3 reasons to leave it on. First to protect the bottom of back of the cap. Second in a rear end collision it adds some protection. Third it keeps that back angle on bottom to less than 10 degrees which is optimum for a rear diffuser area.

Chris D. · 11-05-2012, 06:24 PM

Quote:

Originally Posted by ChazInMT

I can think of 3 reasons to leave it on. First to protect the bottom of back of the cap. Second in a rear end collision it adds some protection. Third it keeps that back angle on bottom to less than 10 degrees which is optimum for a rear diffuser area.

I'm guessing you've never driven a truck with the tailgate down and went over speed bumps.
That will end up destroying the foam over time unless he plans on mocking his shell in glass or bracing the gate so it doesn't move.
A down tailgate wont give you any protection if it just swings upwards with little to no force. Most of everything that's going to hit him will more than likely be a passenger car and the tailgate will just bounce upwards off the rearward cars fascia panel.

I think that ditching that much weight will help far more than a body panel being used as a bumper.

I own the same truck he has and I'm on my 4th rear bumper from rear enders. Silver is a color that just blends in and doesn't get much recognition.

A simple piece of plywood could sufice.
I did something simple and cheap that could be used to subframe the tailgate.

scroll down, mite give ya some ideas. I'm sure that foam isn't cheap and the elections are almost over with, coroplast heaven!

http://ecomodder.com/forum/showthrea...er-2560-2.html

BamZipPow · 11-06-2012, 08:38 AM

Quote:

Originally Posted by Chris D.

I own the same truck he has and I'm on my 4th rear bumper from rear enders. Silver is a color that just blends in and doesn't get much recognition.

You could git one of these to prevent them rear enders...

SUPERBUMPER Hitch Step - Stops Rear End Collision Damage.

I have the Sparebumper one on my truck.

COcyclist · 11-06-2012, 11:10 AM

Quote:

Originally Posted by Chris D.

I'm guessing you've never driven a truck with the tailgate down and went over speed bumps.
That will end up destroying the foam over time unless he plans on mocking his shell in glass or bracing the gate so it doesn't move.

I think that ditching that much weight will help far more than a body panel being used as a bumper

Post #134 show photos of a welded steel frame bolted to the bed that locks the gate down. IMHO the added length will show more gains at the pump than the weight savings from losing the gate, at highway speeds. I think OP wanted it long enough to sleep in too.

a8ksh4 · 11-06-2012, 03:15 PM

Yep, the tailgate has to stay. This is supposed to be an extended camper, so if I took it off, I'd just have to replace it w/ something else to make the bottom of the bed back there. And then I'd have to worry about where to store the tailgate in my garage.

The bumper will still be there, too. I've been rear-ended a couple of times, too... you can probably make out the dent in the passenger side of my bumper.

I got all the wiring done for the new taillights this weekend. I already had a trailer wiring harness installed, so spliced into it's extensions for each of the tail-light pods and added a 6-connection plug to each side. The new lights just plug plug in.

Lastly... I added another layer of foam to each of the side panels for the extension and pretty much got the driver side panel shaped how I want it. I'm going to rough in the shape of the passenger side next and try and get them symmetrical when I finish both sides.

Fiberglass attempt #2 will be very soon...