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Old 04-07-2020, 06:52 PM   #41 (permalink)
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I like the profile shape you've created; it intuitively looks spot-on!

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Old 04-08-2020, 01:13 PM   #42 (permalink)
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trial fit

The aerodynamic gods say 'Thank you!'
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Old 04-08-2020, 04:54 PM   #43 (permalink)
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I'm not sufficiently skilled or equipped to create a compound curve...
The best potential improvement would be to project the curve of the shed's top corners to the forward ends of the outer trusses. This would be a simple curve.

Else you could start with a triangle and bend the tips or slit and overlap as necessary to make a shallow cone shape.
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Old 04-20-2020, 10:50 AM   #44 (permalink)
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Quote:
Originally Posted by freebeard View Post
The best potential improvement would be to project the curve of the shed's top corners to the forward ends of the outer trusses. This would be a simple curve.

Else you could start with a triangle and bend the tips or slit and overlap as necessary to make a shallow cone shape.
For the face sheet, it looks like the leading edge of the center truss just kicks up a bit too much, closer to 1/8" when trial-fit to the truck versus the 1/4" measure on a bench. I'm confident I can remedy this by drilling out the rivets connecting it to the rear panel and shimming it before re-riveting it.

My plan for the side panels is to make them flat 1/8" aluminum, bottom-hinged, sloping to continue the taper of the cab. Once I get those in place and working well, I'll make face panels for them (fastened from behind) that can ease the transition to the top corners, I think your projected curve idea would serve well there, and easy enough to do with a non-corrugated CAD pattern.

These side panels would be able to be removed and/or reshaped in the future when I re-taper the profile of the cap in the more radical phase, keeping the deflector well-suited to that future shape.
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Old 04-20-2020, 10:56 AM   #45 (permalink)
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Unfortunately, a cracked radiator has pulled me away from the fun stuff. Need to repair the lower rad mounts to avoid a repeat, but may take the opportunity to delete the factory clutch fan in favor of a later Ranger electric fan and shroud. The donor trucks for both the radiator and the fan/shroud were air-conditioned, unlike mine, so the improved cooling capacity should make future grill-blocking a low-risk proposition.
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Old 04-21-2020, 02:19 PM   #46 (permalink)
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Bummer! But it sounds you're making the most of the situation and will come out ahead.
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Old 11-10-2020, 07:33 PM   #47 (permalink)
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While a prolonged major move has prevented me from working on the cap, it did force me to make progress in a roundabout way: the Leer fiberglass tonneau, late of a 1990s Chevy Silverado, had yet to be cut into two new smooth side doors. The intact cap was really ungainly, so I figured it was high time I cut out the desired pieces so that it would be exponentially easier to move and store. I measured the angle of the back of the cab and marked out my cut lines. 24 inches was the maximum height I could achieve with that angle, so that’s the height.
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Old 11-10-2020, 07:46 PM   #48 (permalink)
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I borrowed a slick little Festool circular saw and guide to make the cuts and it worked beautifully but for one unpleasant surprise: an embedded steel plate was along my cut line, resulting in the rather pricy saw blade losing a tooth upon impact. I set the depth shallow for a clean cut on that short stretch on each piece and cut through the steel with a better-suited (if less precise) jigsaw. Iím pleased with how these pieces came out, and they are 1) much easier to move, and 2) a bit lighter than I expected.
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Old 11-10-2020, 07:58 PM   #49 (permalink)
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The panels are about 1” thick, comparable to the thickness of the current 1x1 square tubing-framed doors. The outer skins encase what looks like a resin-soaked version of the inside of a hollow luann door. They will need at least a basic perimeter frame of 1x1 to use the existing hinge and latch setup. I’m wondering if I could rout a channel so that the tubing can get bonded to the inside of the outer skin and sit semi-flush with the inner skin? I’m interested in hearing what others may have used to bond aluminum and fiberglass as well. I can’t really work on this for another stretch, so I’ll take some time to play with ideas and do some research.
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Old 11-10-2020, 09:12 PM   #50 (permalink)
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Quote:
Iím interested in hearing what others may have used to bond aluminum and fiberglass as well.
If memory serves there is a trick to that.

?? IIRC It has to do with the chemistry of the bonding agent.

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