SFA all aluminium canopy

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Stef
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Thu Aug 10, 2017 8:22 am

The beginning of our rendition of a canopy; we're not professional aluminium fabricators but not looking too shabby so far

2 full days' work and 2 basic frames done; I now understand why these things are so expensive...it's a lot of work!! Cutting & welding the angles is really time consuming, not too mention the fact that aluminum really warps so there is a lot of checking/measuring in between welds.

IMG_20170809_155653_450x600.jpg
another friend (to the left) with drinks & snacks and to lend a hand always welcome :mrgreen:
IMG_20170809_184703_800x600.jpg

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Mud Dog
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Thu Aug 10, 2017 8:28 am

Looking good so far Stef! :thumbup:
When your road comes to an end ...... you need a HILUX!.

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Hilux Heap
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Thu Aug 10, 2017 8:33 am

Looking Good :thumbup: . I'm in line for one as well :D: :beg:
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Stef
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Thu Aug 10, 2017 8:48 am

Let's see how these two...well 3... turn out. If you still like what you see I could twist some arms to build #4; don't have a price yet but I doubt if it will be much cheaper than the commercially available ones.

Next step is to get some rubber & figure out the doors...want to try something different. Also not going to use alu tread plate so there is some more TLAR'ing to be done

Mars
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Thu Aug 10, 2017 8:49 am

Baie netjies. Met wat sweis julle? TIG?

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Thu Aug 10, 2017 8:52 am

Sure thing Stef :thumbup: . It's all about rhe price LOL :D: :D:
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Stef
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Thu Aug 10, 2017 8:57 am

Mars wrote:
Thu Aug 10, 2017 8:49 am
Baie netjies. Met wat sweis julle? TIG?
Tx :thumbup:

Jip ... TIG met Argon en dun rods. Moes eers 'n pro kry om ons 'n les of twee te gee...maar my mater wie se masjien dit is kom nou mooi reg en ek gaan self bietjie probeer hopelik een van die dae.

Mars
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Thu Aug 10, 2017 9:05 am

Ja as mens daardie TIG eers regkry is dit ongelooflik wat jy kan sweis!!!!

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pieta.swanepoel
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Mon Aug 14, 2017 7:08 am

Ek sal maar volg wat julle doen. Moet self leer swys. Dalk eers met ietsie kleiners begin :)
Groot berge en lang grondpaaie

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Stef
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Mon Aug 14, 2017 1:37 pm

No real progress over the weekend; work among other things...
The fancy gull wing doors to give level access right to the top of the roof inside are not going to work out so lekker with the elements and some of the dimensions, plus it would be an awful waste of the cladding sheet (besides, I hardly ever load right up to the roof anyway).
So the design is being adapted slightly so that the roof skin is closer to the width of a sheet (within 50 mm as opposed to 200 mm), and one sheet basically yields two roof skins. This means that smaller panels are needed for the side doors.

Aiming to have the door frames & gussets done by the weekend

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Bugzy
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Fri Aug 25, 2017 8:45 am

Stef, hoekom se jy die Gull Wing Doors gaan nie werk nie - ek beplan om my canopy so te bou so ek sal graag wil weet hoekom jy so se.

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Stef
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Fri Aug 25, 2017 10:37 am

Hi Buks, eintlik omdat ons heeltemal te opgewonde geraak het oor die aluminium sweisery :laugh2:

Die tubes wat tussen voor en agterste "arches " loop is te naby aan die hoeke in gesweis, maw die deur se raam bo gaan by die kontoer vd "arch" verby steek. Hulle moes minimum 10mm nader na die middel toe wees vir dit om te werk met 20mm raam.
En om die gull wing te doen beteken ook dat jy nie nog 'n tube kan insit tussen voor en agter op die onderste hoek vd arch nie, so mens verloor bietjie strukturele sterkte. Na oorweging of ons moet sny en skuif, het ons toe maar besluit om eerder te gaan vir sterkte as die ekstra moeite vir 'n 100mm wat jy wen boontoe, jy sal dit in elk geval kan bykom van agter af. Plus die cladding werk beter uit met die grootte van 'n sheet.

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Stef
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Fri Sep 15, 2017 6:21 am

Not too much progress made in the last 3 weeks, but in saying that, we are on door design #3, got the cladding & rubbers procured, and some of the cross bars front to back welded in.

This week managed to get 4 x door frames cut & welded together; yesterday the flat bar came in so this is what we ended up with for the final side door assembly:
IMG_20170914_215055_800x600.jpg
IMG_20170914_214930_450x600.jpg

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Stef
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Tue Sep 26, 2017 9:11 am

Frame #3 all welded together; slightly beefed up with an extra arch and using 3mm wall thickness as this one will have an RTT.
Rear door frames welded together for all 3 frames.
IMG_20170925_131422_600x450.jpg

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Stef
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Tue Sep 26, 2017 9:17 am

First 2 frames now look like this
IMG_20170920_211821_450x600.jpg

BernhardSmuts
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Thu Sep 28, 2017 3:30 pm

Hi Guys.

This project looks awesome!

We're also pretty keen to start a project similar to this. I have been researching quite a bit and the info on the Forum is AMAZING!

If possible could you give me an idea of what size aluminium tubing and sheeting you guys are using for your canopy and where you bought it from?

Hilux Regards

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Stef
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Fri Sep 29, 2017 9:06 am

Thank you Bernhard,

There are plenty weird sizes available in Aluminium... :mrgreen: We based our choices on what was available at the local suppliers as places like Huletts would only manufacture on demand with a min qty of 500 lengths IIRC.

We opted for 38mm & 32mm square with a 2mm wall; as mentioned above the third frame has the same but with 3mm walls which is plenty strong but also 50% heavier.
38mm is used for the arches and 32mm for the beams, this is to give a 6mm gap so that the cladding and adhesive will sit on the 32 flush between the arches.
Same concept followed with door frames, used 20x10mm and 3mm flat bar leaving 6mm gap. Reason for the thin door frames is so that the door as well as the rubber seals could all fit within the 38mm of the arches.

I personally do not like tread plate as a skin for canopies; I went for a composite aluminium & HDPE cladding used on buildings that has good wind loading & anti vibration properties. The outside is also pre-coated with a UV resistant coating. I'm also of the opinion that it would have good thermal insulation properties. Downside: hideously expensive and min thickness is 4mm

The aluminium was purchased mostly from NFM in Pta and Eurosteel in Jhb...Eurosteel also has alu plate with nice finishes other than tread plate, as well as normal alu profiles. Seals I got from Pro-auto rubber. Lock & hinges came from Trail Acc in Silverton.

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Stef
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Tue Oct 17, 2017 10:53 am

"Side" project...
IMG_20171013_175457_600x450.jpg

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Mud Dog
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Tue Oct 17, 2017 11:18 am

Coming along nicely Stef! :thumbup:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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Stef
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Mon Oct 23, 2017 5:30 am

Welding all done. Just the finishing, powder coating & final assembly left

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Mud Dog
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Real Name: Andy

Mon Oct 23, 2017 8:44 am

Looks neat Stef! :thumbup:

Any reason why the one has a transverse rip on top while the other two have lateral ribs?
When your road comes to an end ...... you need a HILUX!.

Image
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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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Stef
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Mon Oct 23, 2017 9:17 am

Mud Dog wrote:
Mon Oct 23, 2017 8:44 am
Looks neat Stef! :thumbup:

Any reason why the one has a transverse rip on top while the other two have lateral ribs?
Tx Andy. Really pleased with the way it turned out

To answer your question...Yes, but it's really just a third arch exactly the same as the front & rear ones with the same lateral beams between arches as the other two frames.

The design was adapted for an an over landing rig so basically 2 reasons :
1) It will have a RTT fitted hence the third arch to spread the load.
2) The guy wanted split side doors.

You'll also note that it doesn't have 3 lateral beams, only 2 and these are welded further in towards the middle to exactly match the mountings of the RTT. The middle beam on the other 2 is meant to support the cladding but we didn't deem it it necessary with the reduced span

BernhardSmuts
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Thu Nov 09, 2017 4:04 pm

Awesome! Looks great so far and thanks for the info on all the materials used.

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