Build your own Aluminium Canopy

[pietpetoors]

I am about to start building my own Aluminium canopy for my IFS Hilux. Any photographs, tips and advice would be welcome.

[glevey]

Here is the link to Flickr.

http://www.flickr.com/gp/24703294@N00/49b6d8

Cheers

Geoff

[Scooter]

Hi Geoff

A nice looking canopy, well done on the build. My question to you is how you have sealed all the corners, joins and opening mating joins, from the elements?

Scooter

[glevey]

Hi Scootern
Silicone was put on all the sides of the ally before being pop rivited to the frame. Then alu angle strip was put over all the edges and sealed with silicone.
Rubber strips were then stuck onto the frame for sealing the doors when closed.
Hope this makes sense.

Cheers

Geoff

[cprinsloo]

Hi all,

Here's a link to photos of 2 canopies I saw a while ago. On the overland forum there's also some other canopies.

http://www.overland.co.za/gallery2/main ... emId=14790

Also http://www.overland.co.za/Canopies/

and http://www.overland.co.za/Packing_Systems

A well designed canopy makes camping a lot easier. I'm using ammo boxes at this stage, but it is a schlep, I'm going to change to drawers with side entry. If you want to use drawers, furnlock sliders work well, and they are not that expensive, about R 150 for a heavy duty set of 800 mm.

http://www.furnlock.co.za

You must decide between steel frame or alu frame. Steel is cheaper, you can weld yourself, but it's heavy and it rusts. Apparently very difficult to weld alu yourself. Alternative is to design and cut the frame yourself, and take for some proffesional to weld. You can also pop rivet it together and then take it in for welding. Welding can be R 25 per weld or more.

Think very carefully about your needs, and think long term. Everybody's needs are different, but that makes the building of your own canopy so much more satisfying.

Enjoy!!!

Chris

[Hillbilly]

Hi

I'm new here. I have just completed building my own canopy.

Just came back from a 3 week trip. Canopy worked well. Must still sort out dust at tailgate.

Attached are some photos and basic plan. Total cost ±R7000.00.

Cheers

Marius

[cprinsloo]

Hi Marius,

Welcome to the forum. VERY nice canopy, and the workshop doesn't look to shabby either!!

Cheers,

Chris

[Niel]

Hi Marius, Welcome to the site, nice canopy. I see you are in St Helena baai and close to Pieter in Langeaan. We must get together some time.

[pietpetoors]

Hi Marius
Welcome to the site. I see yo are in St Helena.
VERY NICE canopy.
Did you do the Aluminium welding yourself?

[Family_Dog]

HI Marius,

Welcome to the forum!

I'm sure many members here would be interested in attempting to build a canopy like this, do you perhaps have the various measurements for the framework construction?


-F_D

[Hillbilly]

Hi

A friend that is running the West Coast Welding School did the Aluminium Welding.

I did all the cutting myself (by hand) and we did all the welding after hours and on a weekend. The frame we finished in ±4 hours. The doors and panels took most of the time. I had to cut the hinges smaller and made small cover plates so that it fits on the side of the 50 x 25mm tubing.

All the bolts and nuts are stainless. Couldn't find the toggles (locking mechanisms) in SS.

Overall it was quite a nice to see the project coming together.

The measurements are on the the pdf file that was posted the previous earlier. If someone wants to come and have look or just get ideas, they are welcome to contact me. I work in Vredenburg.

Marius

[Hannes Thirion]

Hi, I am new to this forum, and may'be little late on this topic. But I see Chris already pointed you to the Overland forum where you can find full detail on my alu-canopy as well.
The direct link to it is http://www.overland.co.za/Canopies/Hannes_Thirion.pdf
Dust proof and working well through Lesotho, KTFP and the South of Namibia... my Heimatland.
Regards,
Hannes Thirion

[Niel]

Hannes, welkom by die forum en ek isseker jy gaan dit geniet

[pietpetoors]

Hannes, baie dankie vir daardie verslag. Dit is 'n stukkie werk om op trots te wees daardie.
Wat se rubbers het jy vir die deure gebruik, kan jy dalk 'n naby foto daarvan plaas?

[Hannes Thirion]

Pieter, Sal vanaand of wanneer ek tyd het naby fotos van die rubbers in die deure neem en plaas. Ek het die rubbers by Silverton Canopy Centre gekoop. Ek het D-rubbers in die agterdeur gesit en van die plat skuimrubber op die sykante gesit. Die plat skuimrubber is die met die plakstrokie wat jy aftrek om die rubber te plak. Die deure met dit in maak moeiliker toe as die met die d-rubbers. Ek sal nog met tyd die plat skuimrubberstroke met d-rubbers vervang. Tans het die agterdeur d-rubbers en die valkante weerskante het plat skuimrubberstroke.
Groete,
Hannes

[Tonto]

Eerstens `n bietjie raad. As juy fotos wil saamstuur, cut en paste eers jou text voor jy die goed begin aanlas. Ek het die stuk nou al 2 keer geskryf en as die fotos nie wil laai nie, moet jy maar weer begin.
Nou ja, kom ons probeer weer.

Ek,`n ou groot maat van my en sy regterhand het vir my `n aly canopy gebou. Saans laat gewerk en die ergste van alles, net die laaste aand een bier gedrink. Moet se, na die bier het die inspirasie begin vloei.
Die raam is van 50 x 25 sq sections gebou en is baie stewig.
Die kantvensters is van aly vensters met 5 line treadplate ipv glas. Dit het die hoe koste van gaslifts uitgeskakel en die vensterrame het ook seels om die stof uit te hou. (na `n 100 km grondpad teen die Weskus was ek verbaas hoe min stof ingekom het)
Die agtervenster is ook in `n 50 x 25 raam vir sterkte.
Dit is regtig `n plesier om alles in die hande te kan kry sonder om te sukkel.
Silikoon is gebruik om die dak en agterpanele op te sit. Blykbaar moet `n mens NO silikoon gebruik wat nie met die aly reageer nie.
Die knippe was `n probleem, maar ons het knippe gekry wat flush sit en dus aan niks sal haak nie.
Die enigste probleem met die knippe is dat die slotte nie baie gevorderd is nie, maar hulle kan darem sluit.
Ek glo nie ek gaan sliders gebruik nie om meer aanpasbaar te wees met die pakkery, maar moet nog die agterdeure toerus met kiste vir `n tipe kombuis aan die linkerkant, en `n toolbox/recovery box aan die regterkant.
Ek sal dit waardeer as julle fotos en idees kan stuur.

[Tonto]

Dankie vir die hulp met die fotos Niel.
Ek sal later die A-Z fotos post.
Sal graag idees vir die kombuis en toolbox wil sien.

[Niel]

Plesier, ek het vir jou email gestuur.

[Maniac]

Daai fotos van die deur rubbers word nog steeds in spanning afgewag