Brumby Hard Top Tonneau

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Dean.nabbe
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Brumby Hard Top Tonneau

Post by Dean.nabbe » Thu Jul 10, 2014 8:30 pm

Ok guys.. i've always liked the sleak and stylish look of the Hard top Tonneaus you see around on the new Holden and Ford utes... so, i decided to build one..

this is the start of a progressive thread, i will post pics as the project takes shape..

the plan is to build a tubular aluminium frame out of 25mm with a cross bar at halfway, a fibreglass border that will lip over the edge of the tub(to the rise in the body) then a checker plate rubber cover over the lot. the rubber will serve to give a bit of flex as well as help to seal around the window and body indentation...

so far, i've removed the ladder(from the old tonneau) from the back window and put 50mm x 50mm aluminium angle around the front of the tub to about 600mm.. and built a base frame to be able to support the fibreglass work until it sets..

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i will fill the gaps between the wood and the body with expanding foam, sand it flat and then cover it and the body with a releasing agent for the fibreglass..


to be continued............
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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Dean.nabbe
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Post by Dean.nabbe » Thu Jul 10, 2014 10:11 pm

this is where i got the idea for the fibreglass border..

http://youtu.be/VO4fM0Yg0OU

althought i have decide to use rubber to cover the the majority of the lid rather than aluminium.. as i plan on using it for camping, the rubber will allow me to put stuff that is slightly tall in the tub and be confident the rubber will flex enough to allow the lid to close and latch..
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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Bantum
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Post by Bantum » Fri Jul 11, 2014 8:42 pm

Will have to keep an eye on how this turns out - may want one for my brumby .. :p

Cheers, Bantum ...

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Dean.nabbe
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Post by Dean.nabbe » Fri Jul 11, 2014 10:31 pm

after a bit of thinking, i've decided(for security purposes) i'm gonna do it full fibreglass instead of rubber... although i will still have a rubber surround at the cab to help seal out water..
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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El_Freddo
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Post by El_Freddo » Sun Jul 13, 2014 11:39 am

Personally I'd have the front end raised like a tonneau cover is fitted - this will help out with moving water off that rear wall of the cab.

My 5c ;)

Cheers

Bennie
"The lounge room is not a workshop..."
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El Freddo's Pics - El_Freddo's youtube

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Dean.nabbe
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Post by Dean.nabbe » Fri Jul 18, 2014 4:18 pm

halfway there...

fibreglass release agent(aka packing tape) in place and alloy frame built.

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Temporarily fixed the hinges, will replace with 1/4 inch rivets when the glassing is done. i intend to fix a rubber strip over the hinges that will come out to the end of the body indent.
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next i will cover the frame in flywire(to support the fibreglass) and rivet a 25x60 angle along the side.. this will serve 2 purposes, it will hold the flywire in place, and give me a better overlap to seal along the edge up the front..
Image

to be continued...
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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Bantum
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Post by Bantum » Fri Jul 18, 2014 10:57 pm

Going to put gas struts on it ?

Ciao, Bantum ...

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Dean.nabbe
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Post by Dean.nabbe » Fri Jul 18, 2014 11:04 pm

yep... i need to glass it first so i can calculate the weight and work out what size and length to get
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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El_Freddo
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Post by El_Freddo » Mon Jul 21, 2014 11:51 pm

Looks good Dean!

Going to put any fancy humps/go faster bumps in it like the HSV/FPV stuff has?

Cheers

Bennie
"The lounge room is not a workshop..."
Image
El Freddo's Pics - El_Freddo's youtube

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Dean.nabbe
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Post by Dean.nabbe » Tue Jul 22, 2014 2:47 pm

nah, i did think about it... but decided, since it was a first time build i would KISS it..

just concentrating on functionality, some one else can use my technique(if it works) and make it flash if they want..
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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Bantum
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Post by Bantum » Tue Jul 22, 2014 2:58 pm

Looking good so far ... :like:

I'd put a slight upwards 'bow' in the frame to ensure water doesn't 'pool' on the lid & runs off the sides ... ;)

Cheers, Bantum ...

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Dean.nabbe
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Post by Dean.nabbe » Wed Jul 23, 2014 11:37 am

i'll have a support bar sitting under the centre of the frame whilst i'm glassing so the weight will pull the perimeter down and cause the centre to stay level or high..

because of the joiners i have used in the frame, it does have a small amount of flex atm, but the glass will stiffen that..
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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Dean.nabbe
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Post by Dean.nabbe » Wed Jul 23, 2014 7:24 pm

flywire and angles fitted..

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although the fly wire has proven to be harder to get taut than ariginal expected.. so i will be getting some alloy mesh(security mesh) to put over the centre frame instead..

the joys of trial and error.. :)
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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Bantum
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Go flater ...

Post by Bantum » Wed Jul 23, 2014 7:45 pm

Hmm - to achieve a neater, flat finish on your Fibreglass - I'd put some scrap sheet plywood in the spaces left ( as in a mould ) whilst forming it - then it can be removed after curing - don't forget your 'non' stick covering ... :)

Note: The Ply is ment to be temporary support whilst under construction ( like pouring concrete in a mould )

Cheers, Bantum ...

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Dean.nabbe
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Post by Dean.nabbe » Wed Jul 23, 2014 7:56 pm

i'm trying not to use wood in it's construction.. the base for the glass was bits i had in the shed..

i use to fit hard lids way back when i was an accessory fitter, one brand we used was fibreglass over a securamesh core... they were light weight and rigid.. thats where i got the idea to use the mesh
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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El_Freddo
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Post by El_Freddo » Sun Aug 03, 2014 6:09 pm

So what are you driving while all this is happening?

Cheers

Bennie
"The lounge room is not a workshop..."
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El Freddo's Pics - El_Freddo's youtube

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Dean.nabbe
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Post by Dean.nabbe » Sun Aug 03, 2014 10:28 pm

the old girl has been in the shed for about 2 yrs.. with 4 kids the Brumby just doesn't cut it.. lol

we have the Voyager for the daily drive.. this will be my camping car for when i go away on long weekends with the mates.. I can keep it packed and ready to go and last minute..
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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Dean.nabbe
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Joined: Sun Feb 24, 2013 9:55 pm
Location: Benalla, Victoria

Post by Dean.nabbe » Sun Aug 03, 2014 10:32 pm

as with all first time builds, plans change to suit whats working and whats not..

i am now going to fill the lid with expanding foam, so i can shape it for run off(as suggested by Bantum) then i will glass over the top...

central locking kit should arrive some time this week, so i can fit the spare actuators to the lid and wire it all up...
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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Bantum
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Triton Hard Cover ...

Post by Bantum » Mon Aug 04, 2014 2:51 pm

Just found this for reference :

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Found here : http://www.boostcruising.com.au/car-par ... -Sale.html

Interesting to see if it could be made to fit on a brumby ( You would have to cut in half & take bit off ... ? ) ... :twisted:

As it would save a bit of time if it did ... ;)

Cheers, Bantum ...

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Dean.nabbe
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Post by Dean.nabbe » Mon Aug 04, 2014 3:52 pm

i have screwed and glued a board onto the under side of the frame.. his will not only be a cover for frame it will also be a base for the expanding foam to adhere to..
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i also took a photo of the angles to show how i have made it fit past the body in the lifted position.. the black tape shows roughly where the edge of the lid sits at the front end.
Image

now i'm just waiting on the funds to buy the expanding foam and the fibreglass
[SIGPIC][/SIGPIC]

1987 Brumby.
still to come:
2"exhaust
winch bar

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