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How comfortable are ya going straight with a jigsaw???? Strong the force was with me this morning......Hrrmmmm.... Nice clean edge cut.... Then the side panels were trimmed further to 24 high and 67.5 long..... Some stats that were asked earlier...... The weight of one panel...

Yessir. Wait til you see the now trimmed panels...... Whooooot

Thank you. I will see if I can round up some scraps. As this is a box without a bottom....sorta..... full rigidity and strength done come until it is all assembled and bolted to the truck, but I will see what I can do. I suspect that as I find a piece and treat the edges and corners with...

Video is done. It is long, and perhaps boring but it is meant to show the good and the bad and as such do show mistakes that happens, like laying fabric wrong , and how to fix it....etc....etc. The whole cast took just over 4 hrs and the video was condensed down to 1'ish. I think it hits the...

Ha ha..... well.... Destructive testing is way fun. Many moons ago, I build a bash plate for my then BMW 800GS as I was beta testing a auto clutch from Rekluse. It had to withstand some severe pounding, and I made a few different plates and then shot them with a 40 caliber. I knew it would...

I made a video of the first panel layup. It is long and tedious but it gives you some idea of what time and effort it takes to make a panel yourself. I suspect it will be available on YouTube tomorrow sometimes.

Time to break the mold. This is always so exiting as you truly dont know what ya have until you see it... Ha ha. Top panel lifted.... Plastic pealed back.... As afore mentioned you can get a smooth back side as well as the front side if you just treat the top panel with release agent...

Rolled out the first layer. Then wet it in with another layer of resin....... then cloth. After the first 3 layers, then one more resin...... Then it is time for the foam. Because I had cut mine I used Thixotropic epoxy to fill the crack. 2 more layers of Cloth. Didn't do a very good...

Then you carefully roll the cut fabric up in small rolls. The second change I did was to change the construction from 3 outer and 3 inner layers to 3 outer and 2 inner. There is plenty strength with a total of five and it will save some on the cost. 5 in total. Then it was time to cut the...

Well....... Today was the day casting the first panel. Table marked with 2 inches overlap on both sides. Edges got a layer of plastic where I can set down stir sticks and buckets with resin. Then release agent was poured in a cup to treat the panel. It was plural, and I was going to treat...

First you need to set up a good work station with room to work around..... Then gather all the materials you need at the ready...... I used electrical tape to cover the edges of the particle board. It will off course be treated with release agent but still then, if epoxy gets a good hold it...

I appreciate everyone's input and opinions, and would love to discuss the properties of composites. How ever as I have seen all to often on public forums it turns into a food fight and mods have to get involved and many times the message is destroyed. I welcome suggestions and ideas, even when...

One big roll of Carbon fiber arrived yesterday and Epoxy will be here today UPS says. This begins next week Whoooooot....

As The Carbon Fibers and Polymers are in transit, I started by creating a level platform to cast from. 4 saw horses and three straight 2x4x8's. The table sits on two chips on the floor so I shimmed the 2x4's with popsicle sticks.... Then one sheet of 3/4 melamine covered particle board on top...

The foam core in the middle will be half inch. Add the 6 layers in total .... 60/1000 inch. Total matrix just over 1/2 inch. That is however by choice for about $10 more pr 4x8 sheet you can go to 1 inch or even 1.5 inch and stick with the outer matrix of composites. The construction is the...

A few years back I heavily modified an off road trailer by among other things building a carbon fiber front box making up for about half pf the trailer. It was a great build but as it began someone suggested that I started a new thread. I resisted as I thought it would not be that popular but...

I think you might be best off by posting and surfing the very detailed Smitty thread here in this section.

Mine sat 100% flush on the inside as well. I used 890 or also called pro-seal, which is an aviation grade 2 component seal, and it never moved.

Smitty told me they are of structural nature. Mine went on the inside as well.

Please keep this Bronco focused. It is getting pretty annoying.