DIY Alu Canopy Frame & Front Replacement Bumper.... Updated

[MOFASA]

To spite not getting my bonus from work or even my full salary
I have still managed to do a few of the projects i had planned for this December....

I started with the Alu canopy frame and thanks to a good friend I got the steel given to me......
Spent some time thinking and planning the basic frame and where to start.....
Eventually I got down to the build......

Through cleaning out my garage i found some 4mm plate that was made into hinge extentions for the OLD garage doors and not fitted, so my brain started another design while i was building the canopy....

So i got side tracked for a day and designed,built, painted and fitted a replacement bumper........

Then it was back to the canopy frame.....
My welding is not that gr8 but it holds the weight so im quite happy with it.....
Now all thats left is to build the canopy rear door, clean, paint and clad it with alu.....

[MOFASA]

And here is the bumper

[4x4Maniac]

Nice one Jonno! Looking forward seeing your progress!

[JJBotes]

NICE !!

[Thunder02]

Looking good,can't wait to see end product

[The Legend]

Looks very nice Johnno-You can be proud of your handwork.Keep us update with your progress.

[Haboob]

Looking Good...Keep us updated

[Mud Dog]

Looking good so far!!

[Vlak vark]

Looking good Jono.
As you go allong give us a breakdown on material even if you got it for free.
I'm also going to build myself one one of these days.

[MOFASA]

Thanks guys for all the positive comments............

Looking good Jono.
As you go allong give us a breakdown on material even if you got it for free.
I'm also going to build myself one one of these days.

So far for the canopy i have used...............
1 length of 25x25x1.6 square tube (still some left)
2 Lenghts of 38x25x1.6 rec tube (still some left)
8x M8 cap srews to mount it
And cos my welding is not that gr8 i used about 15 welding rods on the canopy and bumper combined......
Grind, weld, grind weld, grind,weld......... But got it done....

For the bumper i mainly used off cuts from the 38x25x1.6 and then half a length of 25x25x1.6 tube that i still had left from the canopy....
The plates on the bumper i had lying around so put it to good use....

[Vlak vark]

Thanks Jono

[MOFASA]

Thanks Jono

You Welcome........

[Polarbear2008]

MOFASA

By "a length" do you mean 6 metres? I ask, as down here in CT we can buy either 3 or 6 metre lengths of steel (depending where you buy).

Looks very good! I get the idea that the new year has inspired lots of new canopies for some reason!

[DassieHassie]

baie mooi!!

[MOFASA]

MOFASA

By "a length" do you mean 6 metres? I ask, as down here in CT we can buy either 3 or 6 metre lengths of steel (depending where you buy).

Looks very good! I get the idea that the new year has inspired lots of new canopies for some reason!

Theunis Sorre for that... Yip 1 lenght is 6mtrs....
Yea the canpoies are springing up all over the show....

[Polarbear2008]

Thanks Johno!

Now you got me started!

Are you going to Sikaflex the alu to the steel, because one needs to isolate the two otherwise there is a chemical reaction (the caused Landys to ROT not rust!)

The easiest way I see is to use Sika as both the bonding agent and the isolator. This also lets the plates "shift" as the body/canopy flexes in stead of bending and possibly tearing rivets/holes.

Your thoughts?

[Froll]

Job well done Johno. One of these days the people who make canopies will try and put a stop to home made canopies as was done with trailers. I hope I get to make mine before they do.

[MOFASA]

Thanks Johno!

Now you got me started!

Are you going to Sikaflex the alu to the steel, because one needs to isolate the two otherwise there is a chemical reaction (the caused Landys to ROT not rust!)

The easiest way I see is to use Sika as both the bonding agent and the isolator. This also lets the plates "shift" as the body/canopy flexes in stead of bending and possibly tearing rivets/holes.

Your thoughts?

Please explaine this as its the first i have heard about it.......
I was going to paint the frame with ruberising and then silicone and rivet the alu to it......
Would that not stop the ROT as you put it??

Job well done Johno. One of these days the people who make canopies will try and put a stop to home made canopies as was done with trailers. I hope I get to make mine before they do.

I cant see that happening cos you dont need to register the canopy......... So you should have plenty of time

[ThysdJ]

Are you going to Sikaflex the alu to the steel, because one needs to isolate the two otherwise there is a chemical reaction (the caused Landys to ROT not rust!)

It are called galvanic corrosion. 2 different kinds of metal corroding in the presence of an electrolyte.. rainwater will act as the electrolyte..

[Traveler]

Neat job Johno.

[MOFASA]

It are called galvanic corrosion. 2 different kinds of metal corroding in the presence of an electrolyte.. rainwater will act as the electrolyte..

O right

SO will that still take place if the frame is painted with rubberise first and then silicone between that and the alu sheeting....

[ThysdJ]

It are called galvanic corrosion. 2 different kinds of metal corroding in the presence of an electrolyte.. rainwater will act as the electrolyte..

O right

SO will that still take place if the frame is painted with rubberise first and then silicone between that and the alu sheeting....

nope.. Put down a bead of Sika between the frame and the sheet. It will also eliminate rattles.

[Legendary]

Hi Johno

It's looking good.... Need more pictures, I am interested in your corners as they seem very "rounded"?

I start the build of mine this weekend, didn't get much time in December with all the fishing trips I managed to get in.

I will be using the sikaflex on my canopy to seal the sheeting to the frame, but I will also use pop rivets in certain areas (coated in sika) for extra strength.

The sika is a lot stronger than silicone it's like rubber cement....

Now to get A into G and start cutting and grinding.

[MOFASA]

Hi Johno

It's looking good.... Need more pictures, I am interested in your corners as they seem very "rounded"?

I start the build of mine this weekend, didn't get much time in December with all the fishing trips I managed to get in.

I will be using the sikaflex on my canopy to seal the sheeting to the frame, but I will also use pop rivets in certain areas (coated in sika) for extra strength.

The sika is a lot stronger than silicone it's like rubber cement....

Now to get A into G and start cutting and grinding.

Ok Guys where can i get SIKA and how much is it??
Is it applied in the same mannor as normal silicone??

The corners are just normal angles put together then welded not really rounded off at all....
I will take some more pics soon and show you....

[Borntofish]

Builders warehouse sells Sikaflex.

[MOFASA]

Builders warehouse sells Sikaflex.

Thanks...

[MOFASA]

Up date

Bumper complete... top plate in place and i have decided to leave the front open incase i chose to fitt a winch oneday.....

[MOFASA]

Now tell me what you think about the 33inch tyres i want to fit after the body lift....

The pic below shows the wheel fitted and the jack is lifting the body 50mm higher than normal.....
Just done to see what it would look like.....

[Traveler]

Excellent work Johno.

You want to build one for a Patrol?

[MOFASA]

Excellent work Johno.

You want to build one for a Patrol?

but it will have to be on weekend or after hours

[Traveler]

Excellent work Johno.

You want to build one for a Patrol?

but it will have to be on weekend or after hours

Let's talk.

[Froll]

Nice work Johno, gives me inspiration to start on mine.

[MOFASA]

Nice work Johno, gives me inspiration to start on mine.

Then go start it and post your pics....

[smokintyres]

Great work! Especially like those truck roof lights serving as indicators, makes it even more one of a kind

[MOFASA]

Great work! Especially like those truck roof lights serving as indicators, makes it even more one of a kind