Built a couple mock up Hotwire cutters. PVC and lightweight steel tubing build warped too much to hold wire tension. Not going to use any of my good steel material in the garage...
2x3 worked well enough for this use.
Steel angle on each side to hold the tensioning bolts. Two 18v power tool batteries in series with a switch. One 18v worked decent but not enough power to cut even. Need to get some heavier duty tension wire to hold up with the added heat. Then we’ll be in action.
Taking a couple days of finer sanding work to finesse the shape and think it over to make sure I’m happy with the profile.
I’m at the point of starting other projects as a break from my current projects...
wrenched on the bike a bit today and tore it down to do some pre-season work. Good to give the mind a Jeep break but stay active mechanically.
Getting back to the camper top plug & mold. Measured out the rain gutters within a 1/16” tolerance and built up a frame out of 2x3 to hold it in these exact dimensions. Open-ended fiberglass profiles like to flop.
The makeshift sawhorses were far too wobbly at this point so reinforcement came to them as well.
Still need some bondo work.
Need to buy/borrow a 20-30gal compressor to run the spray gun.
Next stage is primer, final sanding, waxing and then mold making.
Its too bad that the Gibson header does not come with any expansion joints like some of the other brands do. I also think that the Cherokee/Wrangler exhaust systems should have a woven stainless flex joint some where in the exhaust piping to allow for movement when the motor torques under load.
Put together the soft top real quick in case we get some rain anytime soon.
Work slowed on the top, taking extensive time in the bondo stage to ensure all is even and the profile I want. Almost a gallon of putty in, so the profile will be a good bit smoothed out and a little different from the original Westfalia shape.
At this point I think I could have made a scratch plug out of foam for about the same hours, as it sands much quicker than bondo... it is nice to have a base shape to draw off of though. I’ll post when I have some more exciting news.