Progress continues, but at a slower pace. Both Michael and I have other commitments which adjust priorities. Luckily, it looks like we’ll both be ready to attach panels at about the same time. I’ve got a lot to report so I’ll break it up into smaller updates.
The plan for the bed cover is to use a donor bed cover from a full size truck. I found one for free from another Ute builder. The donor will supply the main surface of the new cover. Michael will then form new sides all around from fiberglass shaped over a wood form. It’s my job to supply that form.
Now that I have the perimeter of the bed cover defined I can start to build the frame for the fiberglass work. The outer frame is slightly larger than my pattern – just in case. Next I set up the locations for 4 cross bars.
Notches are cut in the frame pieces. Everything is screwed together so it can be broken down during construction. It can then be saved for another build.
I start out with half lap joints but quickly realize that will not work since the cross bars have to taper to a knife edge to meet the frame. So I just use framing screws to hold the cross bars in place.
Meanwhile Michael has cleaned up our donor bed cover. All the supporting parts and internal structure are stripped off.
That took a lot away. The resulting panel is much lighter. We’re pretty sure the adhesive used is Panel Bond. It’s what we are planning to use to mount the panels to the Beetle. That stuff is really strong.
On the next trip to see Michael I get to finalize the fit of the frame. Only a few slight adjustments are needed. If you look carefully you can see there is a pocket to hold the panel from the donor cover. This defines the size & shape we need from the donor panel.
With that known we can cut the piece we want.
The test fit is perfect after a little trimming. The panel has about ½” of rise in the center from the edges. One issue is the top surface of the panel is flush with the wood frame. We want it about half the thickness above the frame so we can taper the new fiberglass border over the wood.
When I get back I add shims to lift the panel up about 0.09”.
The shims go all the way around the perimeter. They have seams to allow the frame to be unscrewed later on.
The next step is to put a radius around the perimeter. The radius is different on the sides verses the front and back. I mark out the edges of the first chamfer and start planing.
After planing and sanding the frame is done. The next step will be laying fiberglass over the edges and creating the final shape.
There is a lot more to do after that. Then we’ll need hinges, seals, latches, and paint.
I've been waiting for an update. Like Pottz says, this has been one hell of a project, requiring a long term dedication and a lot of patience. Great work.
This project is a labor of love (as well as a labor of labor) for both of you. Do you think Michael does many collaborations with customers like this? I suspect that he would rather work alone. He must really trust and respect your design and fabrication skills (and your reliability to deliver your parts when he needs them).
I think of this project every time I drive on a particular stretch of road in Huntsville. The photo is from Google Maps, so it’s pretty fuzzy.
Thanks for the comments! I appreciate them - especially after 27 blog entries.
oldtool - Thanks. The patience is a bit easier since I can work on other things. Plus it takes time to figure out next steps sometimes.
duckmilk - I was thinking the same thing. I started looking for a Beetle in 2022, bought mine in 23, and spent a year getting it in good shape. I'm turning 66 this year and should get it home later this summer.
SplinterGroup - I doubt I'll do this again but Michael might be able to benefit from it. I also saved the forms for building the panels
Ron - Most of Michael's clients are not as involved. He's been fun to work with and we are figuring out things as we go.
If you ever finish... drive yours over to NZ.. all that wood should make it float. They'll give you a bag of kiwi fruit ... more expensive than petrol/diesel nowadays.
If your first cut is too short... Take the second cut from the longer end... LBD
