Wow. Just. Wow.
Your FJ still looks brand new, too. Are the mechanicals all still holding up? How many miles on it now? Asking because I'm looking at a used 2007 . . .
Rob, I would first see if you can bend it back to the form and clamp it without it breaking or cracking. If it can do that, I would apply something like 3M 5200 fast cure adhesive along the ribs and clamp it down again, adding whatever additional fasteners you were going to originally use...
What I wound up using was this: 8 mm (3/8 inch) Falcata Albizzia bender ply short grain, a type of meranti grown on plantations. I bought it from a specialty wood supply place that caters to the wooden ship building trade. They import and export all over the world. You can roll this stuff up...
Rob:
Jess is correct, your cuts are too far apart. I tried to use a similar calculator and it did not work.
For the record, I was never able to get a bend using kerf cuts that did not splinter, and for good reason: I didn't use hot water. If I were to do it over again, I would make the kerf...
"I was using step drill bits to drill these holes as it gave me a nice chamfered edge. My shop tip, mark the flat of the hole size you want to achieve with a Sharpie. That way when the sharpied line disappears you know you are at the right size."
Great tip!
I went through an analysis similar to the one you described. I finally decided on the teardrop style because I did not want to be crawling into and out of a rooftop tent several times a night (I'm a 71 year old male with the smallest bladder in America). Having the trailer lets me park it...
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