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

[freebeard]

Looking good.

Did you sand it the whole way or start with a coping saw, or electric carving knife?

[AndrzejM]

Nice project and good progress. Keep us posted!

[metromizer]

This is a neat build. One thing about cab and beds, that I learned the hard way, is they move independently. The cab is usually mounted to the frame on a 4-6 molded rubber vibration isolators, and the bed solid. The problem is when you bridge the gap between bed and cab, things squeak. This might not sound like a big deal now, but I had a 1/4 'sleeper shell' mounted on one of my trucks that drove me insane, from rubbing and squeaking, until I remounted it, increasing the gap, using a flexible accordion boot to make the connection between the two.

Keep up the good work!

[MetroMPG]

This is coming along nicely!

* Will go ahead and start skinning this pretty soon. I want to see that it's actually going to work and look okay before I start purchasing materials for the rest of the work.

By "work" do you mean aerodynamically?

Once you get the top foam on and radius the transitions, any plans to do A-B-A testing? I see you have a ScanGauge

EDIT: I'm sure you're aware there's going to be negative pressure above the cap at speed; make sure you secure it well to the truck before driving. Hate to see all that work undone following a spectacular lift-off!

[MetroMPG]

Originally Posted by a8ksh4

One of the design features that I haven't mentioned yet is that it's going to have a long recessed compartment on the driver side of the shell where I'll keep a fold out awning. :P

This is getting cooler and cooler!

I assume you mean a flush compartment with a door/panel to preserve good aerodynamics? I look at all the campers & RV's on the highway with all their exposed awnings & supports being blasted by the wind... and cringe a little.

Also, my pie in the sky idea at this point is to glue/clearcoat in a bunch of solar cells on the top similarly to how the all-electric race cars do... Need to see the light at the end of the tunnel before I really even think about this.

And that would be the cherry on top.

Added your build to the front page of the site.

[COcyclist]

Did I miss the post where you told what glue you are using? It looks like white bathroom caulking but I would like to know for sure. Thanks.

[a8ksh4]

Yah, sanded all the way through.

I'm definately not sure how I'm going to mate this thing up to the cab... This feels like the most difficult part of the shell to cut/shape. I'm trying to cut it close... maybe 1/4" gap plus fiberglass, but I don't want it to rub/squeak. If I can find some long-lasting clear tape, I'll cover the paint on the cab where this thing is close and add a foam gasket to the shell that moves and seals.

@Metro... Yah, I'll have to do some ABA testing. I may be reluctant to change much at this point as long as it doesn't hurt my mileage, but I'm really hoping to see a few % improvement. By work, I mean that the aero is there and that I think I can make the finished product look quality.

The compartment/door would deff be flush and smooth. I have to see how ballsy I'm feeling before I'll cut this out of the side... I could mount the awning track on the outside of the shell w/o disrupting flow, as long as the awning bag wasn't hanging off of it, but then I have to think about where to store the bag when I'm not using it, etc... Hmm.

The glue is Loctite PL300 for Foamboard. It's water-soluble and feels like elmers glue, but with more bulk so it can be used to fill gaps.

[ChazInMT]

Originally Posted by a8ksh4

The glue is Loctite PL300 for Foamboard. It's water-soluble and feels like elmers glue, but with more bulk so it can be used to fill gaps.

Heh hehe heh heh....He said " More bulk to fill the gaps!!"

[a8ksh4]

Looks like this foam will flex around a spherical shape just fine, so I'm going to take advantage of the ([edit]In best Bevis creepy laugh: "huh huh huh") tongue and groove and glue 2.25 of these panels butt to butt ("ah huh huh huh") for the top, ~9ft w/ overhang at the back.

[Specaled]

Interesting