t_vago's compound curve foam board pickup aeroshell

[Otto]

FWIW, I'm told that urethane foam may be better from a chemical compatibility standpoint, as Gorilla glue is just liquid urethane. Further, since polystyrene foams are dissolved by polyester resin, you need to use more expensive epoxy with them, another reason to stick with urthane foam in the first place. Not hotwire-able due to toxic outgassing, urethane foam is nonetheless said to be easier to sculpt and shape with sanding, grinding, etc..

For compound curves, consider kerfing the back side of the foam.

[RobertSmalls]

I have a feeling, 2011 is the Year of the Boattail.

[t vago]

Yah, I think so, too. I might start work on version 2 this weekend. Tempted to use something more substantial for the frame than FoamulaR, though.

[t vago]

Oh, and if you do decide to use resin for your fiberglass shell, be sure to completely cover the exposed polystyrene with a good masking tape. It's as what Otto said - Fiberglass resin will very quickly eat FoamulaR (or any other polystyrene).

[RobertSmalls]

Polyester resin will eat styrofoam, and knock you out. Wear a respirator. However, epoxy resin produces lighter composites, evolves much less toxic vapor, and is compatible with foam. At $65/gal, it's twice the price of polyester, but it's money well spent.

[t vago]

Sorry for the confusion - I tend to call polyester resin "resin," and epoxy resin "epoxy."

[KamperBob]

At most home improvement chains you can get foil coated foam board in full sheets. The foiled (not in the Snidley Whiplash sense though) side should be eco(nomically as in polyester) FG resin friendly. The foil layer also provides radiant shielding so your truck bed under such a foam-glassed cap wouldn't become a solar sauna.

BTW, I've found TAPPlastics.com a good place to buy resin and hardner. Anyone have other recommended sources?

[BamZipPow]

TAP Plastics
Instructional videos!!

[t vago]

Here was the final MS Excel workup for the old aerocap


...and here's the workup for version 2

This will give an idea of what the completed version 2 aerocap will look like.

[BamZipPow]

Are you gonna put in a rear window? Is this one gonna be hinged/have a hatch so you have access to the bed?