The plan to make the bed side panels next is being postponed. I need to double check my template for the sides before I commit the design to a build. So – the tailgate panel build is next. 

 

Michael provided a 3D scan of the fiberglass tailgate cover.

 

The file is of a surface with no thickness. That is all I need. You can see that the edges are ragged. The first step is to trim those edges. I have overall dimensions from Michael so I can know how much I have trimmed off. In order to trim the edges I need to set the cutting lines square to the orientation of the imported surface. A few measurements dial that in.

 

Now I can start to get cross section profiles. I start at the far side and then trim about 5 inches off and get another profile.

 

I repeat this until I have 9 profiles. The last 2 are a little less than 4 inches apart.

 

I then start over and create cross profiles.

I repeat this until I have 6 cross profiles.

 

I now have a set of curves that match the scanned image of the tailgate cover.

It’s hard to see from the image but the cover is a bit warped on one corner. This is not a surprise for an unsupported panel. I need a set of curves that are symmetric and that are positioned to support the strips in appropriate locations.

I only need new profiles for half of the tailgate. I can use them for both sides. You can see on the left edge of the image above the slight bit of warp. 

I now have a map of form locations that matches the requirements of the strip layout.

 

The end of the process is to design the forms themselves. The strip plan is shown above the forms.

 

Once the second body panel comes off the forms I can mount these forms on the strong back.