Magoo’s minimal overland tear/square drop

[JasenC]

Looks great, nice job on the door modification.

[Metal_Magoo]

Looks great, nice job on the door modification.

Thank you! It was a brain fart. Surely not the last.

After I started the door I had to move on to skinning the roof and hatch (had to let glue dry). 5’ wide material is much more expensive than 4’, let me tell you lol. Being in the sign industry I have access and accounts to many suppliers. Be it aluminum sheets or other. I decided on ACM or ACP (aluminum composite). We use it a lot. Comes in many colours and finishes. We went with white to match the truck. $187 cnd a sheet for a 5x10. I got two to avoid any seams. It’s about 1/8” thick. Typically for bending you router out the back with a V bit for a kerf cut. I did not. I was worried it would look like when you bend cardboard and you can see the ribs. Worked out fine but it was a pain to manipulate.

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While waiting for that to set up, I finally found some windows. There’s stories about suffocation without proper ventilation. Not a chance I’m willing to take. Originally I only wanted one widow opposite of the door. These were on FB for only $150cnd total. I jump for joy and immediately go buy them. Cut out the windows and router the interior panels for the cut outs.

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[Metal_Magoo]

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You’re pretty much caught up to where I’m at. Skinning the sides are next. Then I can mount fenders and finally decide what the heck I’m going to do for trim!! I can’t find SQUAT in Edmonton. Everything has to be ordered and prices range almost 200%. I’ll be bending my own trim out of 0.080” aluminum if need be.

For a hinge I am going to go with the $6 aluminum piano hinge. Bicycle tube on top and under it. I can’t wait for the $100 hurricane hinge.

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[Metal_Magoo]

So this is where I’m at. The trailer looks so tiny behind the truck haha.

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[JasenC]

Score on the windows. I've been looking for months and it's either nothing or not a decent deal.
Looks good hanging of the truck.

Plan B is make my own out of polycarbonate, Tap Plastic will cut to size for a reasonable price, works out to be roughly 1/2 the price of new windows, if you can get them.

[Metal_Magoo]

It’s been a little while since I’ve been able to work on the trailer. I gave myself a severe concussion back in June.
Anyway, doing much better now so I put in a couple days work.

After the ACM was glued and dried it was time for trim. I used 3/4” aluminum angle with countersunk screws. Absolutely had to use a metal shrinker to achieve the radius. Tool marks need to be sanded out. Not bad for $15.

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[chopperwalker]

What are the specs on your ACM? The front curve looks good and I'm curious how much you can curve them.

[Metal_Magoo]

What are the specs on your ACM? The front curve looks good and I'm curious how much you can curve them.

I think it’s 4mm. It wasn’t very friendly to bend but it did bend. I used ratchet straps and a whack of wooden boards as wedges to really get it evenly pressed down.

Believe it or not, my hatch has either a 4” or 6” radius and I was able to bend it around WITHOUT kerf cuts or v-but grooves.

[Metal_Magoo]

My spouse finished up the headliner this weekend with 1/2” foam and fabric. This allowed me to wire in the pot lights, maxxfan, exterior light, get the interior panels in, and driver side windows installed.

Biggest challenge was making a door, fitting the handle, and installing the AP window with a built in shade.
You must keep in mind that these products are meant for THICKER doors (1-1/2”). I sandwiched the scrap ACM door cut out, 3/8” ply, and then 3/4” ply, and the scrap interior panel door cut out to achieve this. With everything glued, routered, installed, I hung the door and frame permanently.

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[Metal_Magoo]

I didn’t know how to mount square fenders. Lots of people bolt then to the body or weld an awkward bracket off the frame. I kept it simple. Lowes has some steel spacers / stand-offs. I went with 1”. Bolted through the the frame. I bet I could stand on them!

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[JasenC]

Nice call on the fender attachment. I've been thinking of using a little padded fabric as well for the 2 side walls, I have different plans for the ceiling.