Project Extended Pop-Top Aerodynamic Camper Shell ('99 Tacoma)

[ron]

skuff sand inbetween coats for tooth , looks like the surface is already smooth. then after it cures sand down any orange peel and buff it out . alot easier and saves time. same result . and you should be able to touch up in the future if needed.

[freebeard]

I don't think I'd know a clogged nozzle if I saw one, as I haven't really run into to the problem so far.

Must be Karma. They have the clip-on pistol grips with a proper trigger.

[gone7]

Don't forget to clean well after light sanding with dust brushes and a vac or whatever is handy and not scratching, plus a final tack cloth cleaning, between coats.

[a8ksh4]

Have made a little more progress...

I needed a way to mate the shell up w/ the truck, so I assembled some wood trim that set just inside the bed, matched up w/ the sloped sides of the shell, and created a lip that would keep it from moving side to side/forward & back much:


It's all braced up to keep everything square w/ the bed while I start glassing stuff... fits right in the bottom of the shell:



And got it installed for test fit and to work out what size lexan I'm going to need to cut for windows/how big to cut for the back door:




The sliders I was thinking about using turned out to be way too flimsy for this, so I think I'll follow the recommendations a couple of you made here for the lift and just do it manually. I can support it w/ four posts that swing down into place and the shell should be super strong when it's up:


Steps to glass, at this point are:
* Trace outline of front window and cut out.
* Cut out opening for rear door and brace/frame with wood firing strips.
* Glass around front window and front joint w/ top surface and glass up rear door.
* Trace outline of where opening on drivers side will hold the awning and glass top from passenger side across to that opening.
* Cut out opening for awning, gut more of inside of shell, and box in the long compartment where the awning will hide.
* Glass up entire awning compartment.
* Gut the rest of the shell and lay glass on inside surfaces.
* Add reinforcement to mounting points for the lift bars.
* ...
* Profit!

[freebeard]

In the last few days I sat through a 6-part series on Youtube called Moldless Composite Construction, just in case. In the first three and a half minutes of part 5 he shows a method for making a weatherstripped gutter:

Moldless Composite Construction 5 of 6

You may find the whole series of interest. He recommends a spray on polyester primer called Duratech surfacing primer to replace gelcoat.

[a8ksh4]

Great film. Yah, I'll watch the rest of them, too.

[ChazInMT]

Looks great, but what are you going do to fill the gap between top of bed / bottom of cap? Canvas, tarp, panels? You'll need something to keep out rain and bugs while keeping some heat in on cool nights.

[a8ksh4]

I haven't really decided yet, but maybe something like Vintex vinyl/nylon fabric with reflectix radiant insulation on the inside. The Vintex stuff, and probably any vinyl coated cloth, is cool because the seams can just be glued together. No hassle w/ sewing machines.

I was thinking originally about having it permanently attached at the bed and the shell, but it might be hard to manage when putting the top up/down if there's more than one layer (like with insulation). Could attach it at the base of the shell and then fold it down and clip to the bed when the top's up.


Do you have any recommendations on materials to look at?

[freebeard]

A question for anybody?

I'd glue up an air mattress ~23' long and 2' wide, bend it into a U-shape and sandwich it between flanges on the bedrail and cap. Then you could use compressed air to raise the top.

NeilBlanchard -- I'm glad you saw that. It was your CarBEN build thread that got me to sit through it, since I'm not planning on using fiberglass myself. I might not have remembered to post there.

That video had me spitting and hollering at my screen. (First of all was his haircut) He shows as an example a '32 Ford and then builds a '27 style body.

And when he needed a curve for the rear deck, he grabbed a wheel instead of a tire; and only then he starts going on about being careful with your layout.

But he built it and shared, so you have to give him that. (I know it's just an infomercial)

[KamperBob]

Originally Posted by a8ksh4

Have made a little more progress...

...indeed! Looking good. Keep up the great work.