Locost Rear Cover
ala benny_toe
In an effort to keep it Locost and within my skill set I opted for a laminated cover molded over a male mold that would be light, easy to construct, and mount. Research pointed to the pink foam insulation from Home Depot for the buck. Have not seen this material anywhere else. Sure it is elsewhere but I can't prove it. Used the pink stuff because the epoxy doesn't eat it. Just to be cautious I painted the foam with latex.
The pink stuff cuts easily, no power tools needed. Laid the appropriate size on top of my rear frame and traced the outline that I needed. Cut it with a hand held saw that held short Sawzall blades. Rounded the edges with medium coarse sandpaper on a board then marked and cut the holes I wanted. Trim, test fit, trim, test fit, etc.
Sure a coping saw was used somewhere in there.
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Once satisfied with the fit, the male mold went to a set of saw horses covered with plastic. A neighbor donated a roll of 7 oz cloth that was now surplus to him so I bought a quart of epoxy from a local TAP dealer and started laying it up.
I laid 7 layers of the cloth, letting it set up between layers. and it still was pretty light. Not strong enough to sit on but it will do what it's supposed to. If I were to do another I do think I would try mat. Have never worked with mat and I was afraid it might not pull over the edges. Then trimmed and a test fit. I believe that I trimmed it up with an angle grinder but after 4 years that memory is a little fuzzy. It did separate from the mold with ease. Basic woodworking tools was all I needed.
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Tried painting it with red wrinkle paint. Didn’t work. First time using this product and I just couldn’t get it right. Had a good portion of the red vinyl from the dash and roll hoops so I choose to use what I had. Went surprisingly easy. And I like it better than wrinkle paint
Vinyl went on with spray adhesive. Don’t recall which, there are several. One that didn’t work well was Gorilla Glue. 3M has several but you need to pick the right one. They aren’t all alike. And most don’t hold all that well. Opening edges are trimmed with vinyl door edging. Touch of heat helps with the tighter radii as well when stretching the vinyl over the corners.
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Gas filler is from Fisheries Supply here in Seattle. Mainly marine but an awesome hardware store.
For attachment I used these. Called quick latches.
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Got interested in the quick latch when I saw one here on the list. They are $25-26 from Jegs or Summit but the ones I bought came direct from the dreaded China and were less then $6. Shipping takes a while but was free.
Cut a 1 1/2” alloy angle for across the front with a latch in the center to hold it on. One latch each in the rear corners. Hold is quite good. The angle has some foam tape under it to keep a touch of pressure. Takes a little push to get it to catch but it holds down any rattling and keeps things tight.
Covered the angle piece with more of the red vinyl (had to buy a yard so I had lots). I like the way it fits in.
Latch is in the middle on the angle. In situ here.
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Anchored the studs in each corner. 1/8”X 1” alloy
strips provide support for the studs. Riveted in.
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Finished up in Rear Cover continued.