DIY Alu Canopy Frame & Front Replacement Bumper.... Updated
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DIY Alu Canopy Frame & Front Replacement Bumper.... Updated
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.....
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.....
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Last edited by MOFASA on Mon Jan 14, 2013 12:48 pm, edited 2 times in total.
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
And here is the bumper
- Attachments
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- Bumper Replacement (1).jpg
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- Bumper Replacement (3).jpg
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- Bumper Replacement (6).jpg
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- Bumper Replacement (10).jpg (29.94 KiB) Viewed 4734 times
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- Bumper Replacement (11).jpg
- (63.13 KiB) Downloaded 1298 times
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- Bumper Replacement (12).jpg
- (59.53 KiB) Downloaded 1298 times
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Nice one Jonno! Looking forward seeing your progress!
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Looking good,can't wait to see end product
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Looks very nice Johnno-You can be proud of your handwork.Keep us update with your progress.
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Looking Good...Keep us updated
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Looking good so far!!
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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
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.
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.
One life, one dream, one toyota
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Thanks guys for all the positive comments............
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....
So far for the canopy i have used...............Vlak vark wrote: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.
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....
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
- MOFASA
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Vlak vark wrote:Thanks Jono
You Welcome........
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
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!
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!
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
baie mooi!!
Evil thrives when good men do nothing
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Theunis Sorre for that... Yip 1 lenght is 6mtrs....Polarbear2008 wrote: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!
Yea the canpoies are springing up all over the show....
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
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?
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?
01 Hilux 3.0L KZ-TE 4x4 Raider d/c
GME Gx300 29meg & Vertex VX2200 VHF radio
Mikem load springs with greasable shackles and polybushes
Monroe Gas Magnum shocks
Kumho Road Venture AT - 30x9.5x15
National Luna Dual battery system
Frontrunner roofrack with s/steel table
Twin rear high lift jack points
Hilux4x4club sticker! ('nuf said!)
Echo3 4x4 offroad trailer with NL 74 Litre Fridge/Freezer
Dual loadbox slides
Wishlist:
Alu canopy
Warn Winch
Unlimited Fuel & Travel Budget!
GME Gx300 29meg & Vertex VX2200 VHF radio
Mikem load springs with greasable shackles and polybushes
Monroe Gas Magnum shocks
Kumho Road Venture AT - 30x9.5x15
National Luna Dual battery system
Frontrunner roofrack with s/steel table
Twin rear high lift jack points
Hilux4x4club sticker! ('nuf said!)
Echo3 4x4 offroad trailer with NL 74 Litre Fridge/Freezer
Dual loadbox slides
Wishlist:
Alu canopy
Warn Winch
Unlimited Fuel & Travel Budget!
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
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.
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Please explaine this as its the first i have heard about it.......Polarbear2008 wrote: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?
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??
I cant see that happening cos you dont need to register the canopy......... So you should have plenty of timeFroll wrote: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.
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
It are called galvanic corrosion. 2 different kinds of metal corroding in the presence of an electrolyte.. rainwater will act as the electrolyte..MOFASA wrote: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!)
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2010 Hilux 3.0 D4D D/C 4x4 with GOMAD "Brood" Canopy. Tripod.
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
ThysdJ wrote: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....
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
nope.. Put down a bead of Sika between the frame and the sheet. It will also eliminate rattles.MOFASA wrote:ThysdJ wrote: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....
Thys de Jager
CEO and Refreshments Manager at Team Offroad.
2010 Hilux 3.0 D4D D/C 4x4 with GOMAD "Brood" Canopy. Tripod.
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2010 Hilux 3.0 D4D D/C 4x4 with GOMAD "Brood" Canopy. Tripod.
1997 Jeep Wrangler TJ 4.0 Sport. The original SFA. AGA... Gooi kole
email: thys@teamoffroad.co.za
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
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.
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.
They say you are what you eat, however I don't recall eating a LEGEND.
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Legendary wrote: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....
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
- Borntofish
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Builders warehouse sells Sikaflex.
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Re: DIY Alu Canopy Frame & Front Replacement Bumper....
Borntofish wrote:Builders warehouse sells Sikaflex.
Thanks...
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
- MOFASA
- Monster Truck
- Posts: 3095
- Joined: Sun Mar 04, 2012 7:27 pm
- Town: Kempton Park
- Vehicle: 1998 JEEP XJ 4.0............ 4 inch lift.... more mods to follow............ Old vehicle was MOFASA
- Real Name: Johno
- Club VHF Licence: X119
- Location: Kempton Park
Re: DIY Alu Canopy Frame & Front Replacement Bumper....
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.....
Bumper complete... top plate in place and i have decided to leave the front open incase i chose to fitt a winch oneday.....
- Attachments
-
- IMG00004-20130109-0648.jpg
- (133.96 KiB) Downloaded 709 times
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
- MOFASA
- Monster Truck
- Posts: 3095
- Joined: Sun Mar 04, 2012 7:27 pm
- Town: Kempton Park
- Vehicle: 1998 JEEP XJ 4.0............ 4 inch lift.... more mods to follow............ Old vehicle was MOFASA
- Real Name: Johno
- Club VHF Licence: X119
- Location: Kempton Park
Re: DIY Alu Canopy Frame & Front Replacement Bumper....
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.....
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.....
- Attachments
-
- IMG00009-20130109-0959.jpg
- (125.95 KiB) Downloaded 709 times
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
-
- Monster Truck
- Posts: 5311
- Joined: Fri Feb 26, 2010 7:11 am
- Town: Springs
- Vehicle: Pathfinder 2.5 LE AT
- Real Name: Heinrich
- Club VHF Licence: X81
- Location: Gauteng
- Contact:
Re: DIY Alu Canopy Frame & Front Replacement Bumper.... Upda
Excellent work Johno.
You want to build one for a Patrol?
You want to build one for a Patrol?
Know what you don't know.
- MOFASA
- Monster Truck
- Posts: 3095
- Joined: Sun Mar 04, 2012 7:27 pm
- Town: Kempton Park
- Vehicle: 1998 JEEP XJ 4.0............ 4 inch lift.... more mods to follow............ Old vehicle was MOFASA
- Real Name: Johno
- Club VHF Licence: X119
- Location: Kempton Park
Re: DIY Alu Canopy Frame & Front Replacement Bumper.... Upda
but it will have to be on weekend or after hoursTraveler wrote:Excellent work Johno.
You want to build one for a Patrol?
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
-
- Monster Truck
- Posts: 5311
- Joined: Fri Feb 26, 2010 7:11 am
- Town: Springs
- Vehicle: Pathfinder 2.5 LE AT
- Real Name: Heinrich
- Club VHF Licence: X81
- Location: Gauteng
- Contact:
Re: DIY Alu Canopy Frame & Front Replacement Bumper.... Upda
Let's talk.MOFASA wrote:but it will have to be on weekend or after hoursTraveler wrote:Excellent work Johno.
You want to build one for a Patrol?
Know what you don't know.
- Froll
- Monster Truck
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- Joined: Sat Oct 13, 2012 10:13 pm
- Town: Vioolsdrift
- Vehicle: 2010 4.0 V6 Fortuner 4x4
- Real Name: Roger
- Club VHF Licence: N/A
Re: DIY Alu Canopy Frame & Front Replacement Bumper.... Upda
Nice work Johno, gives me inspiration to start on mine.
- MOFASA
- Monster Truck
- Posts: 3095
- Joined: Sun Mar 04, 2012 7:27 pm
- Town: Kempton Park
- Vehicle: 1998 JEEP XJ 4.0............ 4 inch lift.... more mods to follow............ Old vehicle was MOFASA
- Real Name: Johno
- Club VHF Licence: X119
- Location: Kempton Park
Re: DIY Alu Canopy Frame & Front Replacement Bumper.... Upda
Froll wrote:Nice work Johno, gives me inspiration to start on mine.
Then go start it and post your pics....
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
- smokintyres
- LR 4WD Rear Locker
- Posts: 329
- Joined: Mon Jul 05, 2010 10:18 am
- Town: Windhoek
- Vehicle: Hilux 4.0 V6, relatively standard; for now...
- Real Name: Gernot
Re: DIY Alu Canopy Frame & Front Replacement Bumper.... Upda
Great work! Especially like those truck roof lights serving as indicators, makes it even more one of a kind
- MOFASA
- Monster Truck
- Posts: 3095
- Joined: Sun Mar 04, 2012 7:27 pm
- Town: Kempton Park
- Vehicle: 1998 JEEP XJ 4.0............ 4 inch lift.... more mods to follow............ Old vehicle was MOFASA
- Real Name: Johno
- Club VHF Licence: X119
- Location: Kempton Park
Re: DIY Alu Canopy Frame & Front Replacement Bumper.... Upda
smokintyres wrote:Great work! Especially like those truck roof lights serving as indicators, makes it even more one of a kind
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP ..... You wouldn't understand....
[rimg=206x128]