29 replies to this topic

[bert998]

The way old school trimmers do it on custom hot rods is to fit up your sheet of wood, then the curves are created by layering up sheets of card (layering to give strength) and profiling the shape of the roof lining. This would then be covered in a layer of foam however and upholstered.

[Big Guns]

Hi Bert. Old school skills are fantastic. The clue is in the word "skills". I'm pretty good with wood (and a poet!). I don't want to set myself up for a fall but I'm confident I can do it....
Cheers....Dave

[bert998]

if you want more details on the subject pm me your address and i'll mail you some guidance on the subject, I have a book here which covers the subject.

[roofless]

lightweight MDF soaks up water like weetabix - it'll expand quickly in the cold moist air. It also doesnt cut or machine too well.
FR MDF is better for cutting, forms well but doesnt bend to form tight radii
Ply would be a better choice but is brittle in thinner form

Heavier grades of MDF can be soaked with warm water to make them more malleable to create curves.

melamine face hardboard, 3mm or 4mm would be the better choice - moderately resistant to ambient water / moisture ( thats why they use it in caravans and kitchen cupboards ) hard wearing on the face, and forms to gentle curves reasonablly easily - again tight radii wont be achieveable.

foamex is another good choice - rigid, water resistant and forms curves great, can glue to it, even staple to 5mm with low pressure. it'll also form tighter curves if you want them by applying a little heat.

compound curves will be your problem - if the material needs to curve in 2 or even 3 directions ( compound curve ) most timber based materials will struggle, foamex would be best here.

you could always laminate up very thin sheets with suitable adhesive to form the interior roof skin, and some of the best i have seen have laid GRP onto the roof interior to form a 'shell' which is then worked on outside of the car to create exactly what you want.

Edited by roofless, 12 November 2009 - 10:54 AM.

[Big Guns]

Cheer Roofman. I thought about foamex or Brett Martin Foamalux with a gloss finish. The problem with them is condensation. I did a race transporter once with foamex and it "looked" great.....until I slept in it! It was lie a waterfall in the morning! Not that I'm planning on sleeping in the Clubby! The good thing about MDF is you CAN bend it both ways by shallow routing grooves in the back. Also you can PVA seal it to block moisture ingress. Also, it paints very well and the sound proofing is superb and creates a better "atmosphere" for music.
Cheers.....Dave

[Brams96]

Just a thing to add. If you laminate 2 3mm layers of MDF it is really solid. I went over a resonably large bump today and hit my head, it was like getting hit on the head with a bat!

[Big Guns]

Just a thing to add. If you laminate 2 3mm layers of MDF it is really solid. I went over a resonably large bump today and hit my head, it was like getting hit on the head with a bat!

Ha Ha. That'll teach you to "aim" more carefully. Still going for the single sheet option first. Just waiting for a quiet time when I can do it uninterupted. Pics will be posted when it's done.
Cheers....Dave

[Brams96]

Yeah that'll teach me!

[Big Guns]

Hope you didn't damage the lining? lol

[Brams96]

I haven't got round to putting the lining in yet, I need the funds to buy a new black one and some new screen rubbers. I'll get round to it after x-mas probably. Just discovered some rust coming through else where so I might take care of that first.

[camp freddy]

what about mozaic or sistine chapel design

[camp freddy]

what about a vinyl headling ???

[roofless]

what about mozaic or sistine chapel design

I could print it and stick to the MDF

[joakwin]

i did 3/4 mdf on the roof of a truck before
i had 4 layers of d-mat extreme and the roof was still flexing real bad
so i glued the 3/4 mdf to the roof and after that it was like a rock
and then rhino lined the wood
and then i put the stock headliner back up their and no one could tell
the differents but the roof made a thud sound when you hit it from the outside with your hand

but then again 2 18inch subs and over 4kwatts rms does make sheet metal flex alittle

http://viewmorepics....mageID=10729195

Edited by joakwin, 18 November 2009 - 11:30 PM.

[Big Guns]

You guys are MAD!!! I'm too old for banging sounds and too unsaintly for the religeous theme! lol No, I'm going to paint, yes paint, a nice big Union Jack on it....God bless the Queen! lol