Cheap,Tatty, incomplete or almost destroyed tonneau cover wanted

[jaguartvr]

I'm after an old roof cover so that I can make a mould for a solid roof cover for a 250 replica. It will make it much easier to make, I know they fetch a decent sum in good condition so I'm hoping someone will have a cheap one in horrible condition as it probably won't survive the moulding process. Photo to show what I am after and so you can see what I am planning.
The new cover will take the shape of the original tonneau cover but extend over the rear bulkhead.

 

[RickyBobby]

I'm after an old roof cover so that I can make a mould for a solid roof cover for a 250 replica. It will make it much easier to make, I know they fetch a decent sum in good condition so I'm hoping someone will have a cheap one in horrible condition as it probably won't survive the moulding process. Photo to show what I am after and so you can see what I am planning.
The new cover will take the shape of the original tonneau cover but extend over the rear bulkhead.
View attachment 256099

I've managed to aquire 2 tonneau covers - happy to loan you one to complete your intended project

 

[jaguartvr]

Thanks for the offer but you wouldn't be happy with the state they would be returned in. It will be covered in gel coat and fibreglass resin, although I hope 95% of it will come off when the mould is released I can see a lot of it being left behind.
really need a sacrificial one.

 

[RickyBobby]

Thanks for the offer but you wouldn't be happy with the state they would be returned in. It will be covered in gel coat and fibreglass resin, although I hope 95% of it will come off when the mould is released I can see a lot of it being left behind.
really need a sacrificial one.

No worries - let's see how you get on but always happy to serve as the sacrificial lamb if you offer me a commensurate discount on the planned end product

 

[jaguartvr]

More than happy to do that, if you need any parts I can supply just about everything. Can also offer advice on any problems you may hit.

 

[RickyBobby]

More than happy to do that, if you need any parts I can supply just about everything. Can also offer advice on any problems you may hit.

Be careful what you wish for
Seriously though message me your address and I'll get it posted out unless you live near Sheffield or Crewe- in which case I'll drop it off

 

[jaguartvr]

Many thanks for the offer but I really don't want to ruin a perfectly good one. I'm hoping someone will have a damaged, faded, with faulty clips that they will sell cheaply to me.
I couldn't take someones good one knowing that I will almost certainly ruin it.
This is going to fit a 250 California kit but I hope to be able to do one for a Tribute 250 swb as well as I use the same rear bulkhead in both.
Again many thanks for the very generous offer.

 

[IainP]

I'm after an old roof cover so that I can make a mould for a solid roof cover for a 250 replica. It will make it much easier to make, I know they fetch a decent sum in good condition so I'm hoping someone will have a cheap one in horrible condition as it probably won't survive the moulding process. Photo to show what I am after and so you can see what I am planning.
The new cover will take the shape of the original tonneau cover but extend over the rear bulkhead.
View attachment 256099

Can I suggest you just use a fabric reinforcement such as Lantor Soric? If you were adding to the tonneau itself it would be fairly tricky. Soric in 3mm has enough ridgidity it should be easy to fold into position for the Center section, cut and hot glue either end, even make a few ribs in foam board if necessary . Coat of resin and go from there.
Soric is a bit like coremat, but more rigid, it has a hexagon structure to prevent it crushing under vacuum infusion.
Just been out to check, I don’t have any 3mm here I could send, have some 2mm, but I don’t think it’s quite stiff enough.
I get mine from Easy Composites.

 

[jaguartvr]

I was intending to use some 2mm polypropylene sheets GRP doesn't stick to it. I was going to tape it to the top of the front of the rear bulkhead and back to the top of the tonneau cover and tape it into position.
I was then going to stuff the gap between the forward edge or the rear clam where it follows the edge of the roof, maybe using damp newspaper. I was then going to fill it with drywall adhesive to smooth it out, easy to sand and contour.
Once I have the shape (even with the ridge of the polypropylene sheet) I can gel coat it and a couple of layers of matting. This I can then remove to give me a very rough mould. I will then take a rough panel from this mould that I can fit, finesse and sand until I am happy with it and then take a final mould from it. I need to make it as low as possible but allow the roof to fold underneath it. Photo of Tom's build below showing what I am after.

 

[ExMX5owner]

I was intending to use some 2mm polypropylene sheets GRP doesn't stick to it. I was going to tape it to the top of the front of the rear bulkhead and back to the top of the tonneau cover and tape it into position.
I was then going to stuff the gap between the forward edge or the rear clam where it follows the edge of the roof, maybe using damp newspaper. I was then going to fill it with drywall adhesive to smooth it out, easy to sand and contour.
Once I have the shape (even with the ridge of the polypropylene sheet) I can gel coat it and a couple of layers of matting. This I can then remove to give me a very rough mould. I will then take a rough panel from this mould that I can fit, finesse and sand until I am happy with it and then take a final mould from it. I need to make it as low as possible but allow the roof to fold underneath it. Photo of Tom's build below showing what I am after.
View attachment 256225

That is an interest method you suggest there, hmmm. Food for thought, I was going to build preliminary male plug from balsa, having built a few model boats and aircraft in my time. I will rethink that.... I have attached a few pictures of the method I used for a very complicated shape, maybe they will help your thought processes.



These became the half plugs for a big silicone mold, notice the use of stainless mig wire for getting the curves right...The foam is closed cell modellers foam, polyurethane I think, sands well and fairly forgiving, good for aircraft wings etc..Either way, I will watch this thread with interest if it goes that way, because a cover with subtle humps is my next DIY, as long as it fits in the trunk when halved.

 

[Zephyr]

There is a product called plasti-dip.
liquid self adhesive plastic in aerosol cans, that peels off easily.
maybe you can use this to cover a tonneau without destroying it.

 

[jaguartvr]

I'll start a new thread on the rebid section for discussion on the making of the tonneau cover and leave this one open in the hope that someone has an old tonneau cover.

 

[IainP]

You folks are far too creative.
There’s an excellent tape my lad uses when making resin tables, kind of like black electrical tape, but 50mm wide. I’m sure it’s from Screwfix, but I’ll find out and post in this thread.