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Dean.nabbe wrote:now i'm just waiting on the funds to buy the expanding foam and the fibreglass

That's always the fun bit

Cheers

Bennie

poured the expanding foam today but need to get some more..
i want to have about 25mm above the frame all round, this will give me room to shave it back to a uniform 20mm at the front then slope it down and out for run off..

cut and fitted gas strut mounts, lock rods are being modified to bolt straight to the end of the actuators.. central locking actuators are fitted to the lid and switch is wired inside the cab.(just need to run the wire to the tub and connect it)

i've wired the switch so the lid will lock/unlock via the switch, but will also lock(but not unlock) with the central locking remote... that way i can walk off, press the button and know that everything is locked up and secure but it won't unlock when i unlock the doors(that way i don't have to have the doors locked to stop the lid opening when i drive)

all the foam is now poured and expanded.. now to shave and shape... will post some before and after photos for you guys when i get it done

Well, it's now saturday! Don't keep us waiting too long

Cheers

Bennie

started shaving the foam.. not as easy as i expected on my own due to the span..





waiting for a mate to come give me a hand to finish it off..
i plan to shave it to a uniform 20mm above the frame. then leaving approx 1/3 at 20mm, i will shave and slope to 0mm at the back of the frame.

got the foam shaved down to a uniform 20mm and drew a template of the rough sloping shape to follow..

now the fun begins.. the foam is a lot denser than i expected which made it hard to cut, bring on the belt sander for the rough shape, then i'll hit it gently with a sanding block to make the finer touches..

i got some shaping done today.. the rough product is finished, now to just do a little bit of tidy up around the raised arc..






the front(closest to the cab) end is at a nice 20mm about the frame and the edges are tapered off to accept the fibreglass.

Looking good there ...

Found another one that might interest :



More images to be found here : http://www.ausubaru.com/coppermine/thum ... =94&page=2

Cheers, Bantum ...

mine will pivot from the back window, so no wasted tub space

Ok - try this one on for size :



More info here : http://z15.invisionfree.com/Mv_Brat_Bru ... topic=1207

Cheers, Bantum ...

^ Checkout those flares!!

Awesome!

Cheers

Bennie

Sorry it's been so long since I updated.. Been a bit busy to get out in the shed..

First layer of glass is on and looking great.

El_Freddo wrote:^ Checkout those flares!!

Awesome!

Cheers

Bennie

Those flares are a neccessity because underneath that particular Brumby is all WRX - crossmembers, struts, brakes, everything
No Brumby suspension parts whatsoever............

Got the 2nd layer of glass on today, will take some pics for you tomorrow.. Next job will be to fill in some dips and drops with some bog before applying the next layers of glass..
I must admit, I'm kinda proud of myself. It's looking better than I ever expected it to since I've never done anything like this before.

ok, here are some pics of the fibreglass work in progress..
the glass mat you can see will be the next layer.
because of the frame and foam, the next couple of layers will just be around the edge to give the unsupported sections a bit more strength.. the corners i have put an extra reinforcement piece in as well.. when i'ts all done and cured i will trim it off to level with the bottom of the chrome trim.. then put a pinchweld rubber seal around it..

Thats coming along nicely mate.

Thanks mate

she's off the ute.. tomorrow i will relocate it outside so it can bake in the sun for a few days and really harden up the resin like rock(as advised by a fibreglassing expert).
then i can sand out any big imperfections, give it a coating of spray putty to cover any little imperfections, then paint it..

this was the initial trim so i could take it off the ute. i have since trimmed it to the black line and put the final dress layer of glass..




i put the pinch weld seal on to give you a better idea of the finished edge.. although it is only on the initial cut, so it will actually sit about 10mm higher on the final product.




now i can start cleaning the ute and preparing it to fit the finished lid..

i'll post more photos soon..

Awesome work mate.

Love your work! When do you start taking orders and go into full production?