Smooth epoxy/fiberglass layup

[drmiller100]

I can farmer weld steel - lots of penetration, lots of weld, super strong, looks like crap.

I can teach others to be a GOOD welder. One guy worked for me last year I hire to come back and weld stuff for me - he has moved on to another car builder but we are friends.

I am HORRIBLE at body work - absolutely no patience for it.

[skyking]

If I have time to set up and get things dialed in, I can make pretty. I will be doing that soon for my "headache rack" behind the cab. I picked up the steel yesterday. 1.5 square by 0.072, it is going to be a multipurpose mount for a ladder rack, my aeroshell, travel trailer deflector. I will have to take my time with this as it will likely be out there in the public as long as I have the truck.
Now the bumper frame is a different subject. If you want to lay on your back and criticize my welds, be my guest

[skyking]

This might be the solution, If only I could find a sample of it to try:
GBC EZLoad Nap I Educational Roll Film 3 Mil 25 x 250 Box Of 2 by Office Depot

It is 3 mil. One box of it would last me a long time.

[turbothrush]

Originally Posted by skyking

it is going to be a multipurpose mount for a ladder rack, my aeroshell, travel trailer deflector

Great idea!
The aeroshell, will it be polystyrene foam covered with glass and epoxy?

[skyking]

look at my truck pic. It will be 4 MM Meranti marine ply finished bright.

[Ken Fry]

Originally Posted by drmiller100

I can farmer weld steel - lots of penetration, lots of weld, super strong, looks like crap...

... I am HORRIBLE at body work - absolutely no patience for it.

Funny, sounds just like me. I used to teach welding. I can easily get lots of penetration, especially on thin pipes -- blast right through all the time.

Ditto re body work... right on my patience edge.

We should work together -- we could make some really ugly stuff!

[skyking]

I have the bumper installed on the truck, and all the lovely welds are quite out of sight

[Ken Fry]

Originally Posted by skyking

look at my truck pic. It will be 4 MM Meranti marine ply finished bright.

How cool! Did you do it stitch-and-glue style? My POC prototype is mainly 4mm okume, skinnned in and out with 4oz glass in the central tub area, and unskinned in the unstressed areas. The stuff outside the central fuselage (fenders and wings) is Lite Ply (1/8" white poplar).

[skyking]

No, it has 2x2's behind the joints, cut out with a dado to leave a .75" square void. This was filled with quartersawn Sapele` to form the dark red trim wood.
I used cheap virola marine 3/8's.
I glassed the insides and back only with 4 oz. Outside is epoxy coated, and we shoot system 3 WR-LPU glossy over that this weekend with any luck at all.
If I had it do do over again, there are a ton of things I'd change. Send me a PM if you want the build pics, I am holding off posting them till it is substantially done.

[skyking]

I got a sample of the GBC film I linked above from Home Depot. It looks very promising! I will get some when I do my next layup, probably the glass over the aeroshell.