My attempt @ DIY Canopy

esajoda · Post by **esajoda** » Sun May 24, 2009 1:15 pm

Ok seeing that I need to mount a RTT and unfortunately the canopy that came with the bakkie is useless for this purpose I decoded to give it a go at building one.

More next week.

Post by **Mud Dog** » Sun May 24, 2009 2:32 pm

So far so good. The square sides rather than angled might not look as good but will give you a bigger base on the top of the canopy. I assume you're still going to add more centre slats. No need to put them so close though .... extra weight. Alu plate is surprisingly strong. We'll watch for the next set of pics. :D

esajoda · Post by **esajoda** » Sun May 24, 2009 4:03 pm

Sides have a 7 degree slant, just to give it a bit of shape.

On the top its not getting any more slats, those are close to each other so that the RTT can mount on those lats.

legend35 · Post by **legend35** » Sun May 24, 2009 4:46 pm

Are you going to put canvas or alu?

esajoda · Post by **esajoda** » Sun May 24, 2009 6:11 pm

Aluminium

Spartan · Post by **Spartan** » Sun May 24, 2009 6:25 pm

Ek wil nie vir jou vertel hoe om jou goed te bou nie maar die manne het n punt beet met die ekstra dwarslatte as jy aluminium gaan, sonder dit gaan jou plaat rattle en uiteindelik gaan dit uit skeur. Just a thought

Harold · Post by **Harold** » Mon May 25, 2009 7:17 am

Am most interested in your DIY canopy as am wanting to build one myself to replace my 11 year old steel canopy which is showing signs of its age, rust & cracks.

Question: What thickness aluminium plate will you use?
How will the plating be attached to the frame - tack welding, rivets or bolted on?
How are you going to seal the canopy against leaks?
How do you cope with the different expansion and contraction rates between steel tubing and aluminium?

esajoda · Post by **esajoda** » Mon May 25, 2009 4:16 pm

I will accept any advice on what works and doesn't.

The plan is to use 2mm thick alu.
will be using rivets (stainless steel)
will be using a silicone sealer
will find out about differrent expansion rates when its all done, but don't see an issue if I rivet.

Bushwacker · Post by **Bushwacker** » Mon May 25, 2009 4:19 pm

How bout using thin double-sided tape with the rivets, it should stop all rattles

Mr_B · Post by **Mr_B** » Mon May 25, 2009 4:30 pm

Could be useful to use that wind seal foam, with sticky tape the one side, having this between the frame and alu sheets will stop rattles, the foam seal comes in rolls with various widths and thicknesses, then use decent silicone as well to waterproof the joints/seams...

B

Post by **Mud Dog** » Mon May 25, 2009 4:35 pm

Expansion rates are not a problem, use rivets. Don't use any foam type tapes or such like inbetween, they are not water tight and tend to in fact hold water, thus promoting rust on the frame. Use acetic silicone sealant which will also stop any rattles.

Mr_B · Post by **Mr_B** » Mon May 25, 2009 4:52 pm

Years(many

) of wisdom have spoken... thanks Andy I'll bear that in mind when I get to build a canopy one day!

B

esajoda · Post by **esajoda** » Mon May 25, 2009 5:01 pm

Thanks for all the info so far, don't stop, just a pity that I have to wait until the weekrnd to carry on with the canopy.

Presently sitting at the Southern Sun in Maputo by the pool side looking out onto the bay.

Mr_B · Post by **Mr_B** » Mon May 25, 2009 5:05 pm

Shame... :evil:

Harold · Post by **Harold** » Mon May 25, 2009 5:28 pm

Was at Ithala earlier this week and met a fellow who had made himself a canopy.

He had used Tectane 1030 as a sealant – apparently very good. Available from Ben Braven http://www.denbraven.co.za Well worth having a look at the product.

Post by **Mud Dog** » Mon May 25, 2009 6:32 pm

Den Braven products are definitely good, normally superior grade stuff, but sometimes not readily available. A sealant is far better for this application than double sided tape (even the outdoor grade which is a thin rubber, not foam). Tapes don't take up inperfections in joints and welds, whereas the sealants do. Why I suggested acetic silicone (or one also suitable for metals) is because they're relatively inexpensive, readily available at any hardware outlet and do the job.

Scooter · Post by **Scooter** » Tue May 26, 2009 7:25 am

Dont forget that a few guys have built there own canopies on this forum.

Check this out for a few ideas: viewtopic.php?f=41&t=325

IIRC the BAAS (Pietpetoors) used Sika Flex (not sure which one though) to secure the panels for his off road trailer, check this out :
http://www.pietpetoors.com/trailer/

esajoda · Post by **esajoda** » Tue Jun 02, 2009 10:01 am

Eish, picking the frame up from the powder coaters this afternoon, bought all the door rubbers, push button locks and gas shocks yesterday.

Today will take delivery of the aluminium chequered plate and a few other odd pieces and the mounting will start.

I want to mount the gas bottle holders on the outside of the canopy and have decided to build my own, has I am tired of laughing every time I enter an accessories shop and they quote me their prices, one favour to ask, anyone on this forum living around Benoni that is a pro at welding? That I can ask to weld the holders that I have made.

Will attach more pics tonight.

Cheers Jose

Post by **Mud Dog** » Tue Jun 02, 2009 11:16 am

anyone on this forum living around Benoni that is a pro at welding? That I can ask to weld the holders that I have made.

Why not do it yourself .... you did fine with the frame, and if it's stainless, just get a couple of stainless arc welding electrodes. They work well, just a bit dicey on thin material.

esajoda · Post by **esajoda** » Tue Jun 02, 2009 11:37 am

Naah I just have these visions of a number seven gas bottle rolling down the road cause my welding didn't hold.

Niel · Post by **Niel** » Tue Jun 02, 2009 10:18 pm

Scooter wrote:IIRC the BAAS (Pietpetoors) used Sika Flex (not sure which one though)

Sika 221 was used for the Alu canopies. I did not use pop rivets to attach the fixed panels only Sika 221 (glued)

Post by **Mud Dog** » Tue Jun 02, 2009 11:06 pm

Sika make excellent products

Niel · Post by **Niel** » Tue Jun 02, 2009 11:22 pm

The 221 is a non corrosive adhesive for aluminum where as "normal silicone" will cause corrosion on alu.

Post by **Mud Dog** » Tue Jun 02, 2009 11:32 pm

Silicone is not just silicone, is not just silicone :D There are many different types for differing applications .. acetic is for use on metals, etches in. There are alkali's for wood etc., they are the more common variety and will cause corrosion on certain metals. Some silicone's are even hygroscopic, absorbing moisture and promoting rust on metal.
Read labels carefully before buying.

esajoda · Post by **esajoda** » Thu Jun 04, 2009 9:48 pm

Ok here are the pic's as promised.

My first attempt at cladding ended up with me having fun with a 10 pound hammer, I made a mess but at least I felt better. :)

BenHur · Post by **BenHur** » Fri Jun 05, 2009 6:24 am

Looking good

ThysdJ · Post by **ThysdJ** » Fri Jun 05, 2009 7:50 am

Very nice!!

Post by **Mud Dog** » Fri Jun 05, 2009 8:48 am

I'm sure you'll keep us posted, nê!

Post by **Family_Dog** » Fri Jun 05, 2009 3:24 pm

It's looking great, Jose!

-F_D

esajoda · Post by **esajoda** » Wed Jun 10, 2009 11:06 am

Ok basic canopy finnished and sort of ready for use this weekend?

Post by **Mud Dog** » Wed Jun 10, 2009 7:30 pm

Looks very functional! I like the table door and the little gas rider stays!

Dadz Toy BFI · Post by **Dadz Toy BFI** » Wed Jun 10, 2009 7:40 pm

Very neat work Jose

Could you give us your costings asblf man

Scooter · Post by **Scooter** » Thu Jun 11, 2009 7:28 am

Mooi man

What did you eventually use for sealing the plate?

esajoda · Post by **esajoda** » Fri Jun 12, 2009 7:39 am

I used acetic silicone and loads of poprivets. Luckily a mate of mine lent me his air operated rivet machine.

falcon · Post by **falcon** » Fri Jun 12, 2009 11:06 am

Dadz Toy BFI wrote:Very neat work Jose

Could you give us your costings asblf man

BUMP COST ????

legend35 · Post by **legend35** » Sat Jun 13, 2009 8:50 am

Very nice Jose.The weight on the back wheels makes a huge diference when 4x4ing.

esajoda · Post by **esajoda** » Wed Jun 17, 2009 7:59 am

Will work out costing this weekend, now that I have time on my hands, but what I can say is that it will not be more than 6,5 K (that is including school fees).

L35, what is nice about the weight is that it has made the van a bit more level so when the fridge and water tank is installed I should have a perfectly level van.

Spartan · Post by **Spartan** » Wed Jun 17, 2009 7:54 pm

Daai canopy gaan deur en deur die moeitewerd wees en vir die prys

En wat gaan hy kos as jy vir iemand anders een bou

terg net

esajoda · Post by **esajoda** » Thu Jun 18, 2009 8:24 pm

Ok here we go with the costs to build the canopy, this is for the basic canopy.

Steel R 800.00
Aluminium R 2522.00
Hinges x9 R 400.00
Locks R 970.00
Door Rubbers R 500.00
Gas shocks R 360.00
Odds&Ends R 500.00 ( Grinding disks/welding rods/pop rivits/silicone etc)
Powder Coating R 450.00 (Oops forgot to include )

Total R 6502.00

Dadz Toy BFI · Post by **Dadz Toy BFI** » Thu Jun 18, 2009 8:58 pm

esajoda wrote:Ok here we go with the costs to build the canopy, this is for the basic canopy.

Steel R 800.00
Aluminium R 2522.00
Hinges x9 R 400.00
Locks R 970.00
Door Rubbers R 500.00
Gas shocks R 360.00
Odds&Ends R 500.00 ( Grinding disks/welding rods/pop rivits/silicone etc)

Total R 6052.00

Six Grand well spent

Spartan · Post by **Spartan** » Fri Jun 19, 2009 5:50 am

It is normally the labor that takes allot on the price

Post by **pietpetoors** » Tue Jun 23, 2009 9:27 pm

Looks very good Jose, well done

esajoda · Post by **esajoda** » Mon Jul 13, 2009 9:42 pm

Ok, had some spare time this weekend and so decided to give the Kitchen a go, here are a few pics just missing the Coffee mugs and the small Spice rack and of course a good varnishing.

Niel · Post by **Niel** » Mon Jul 13, 2009 11:25 pm

Jose, die kombuis lyk baie netjies

Spartan · Post by **Spartan** » Tue Jul 14, 2009 3:46 am

esajoda · Post by **esajoda** » Sun Aug 02, 2009 9:42 pm

Ok, Canopy is finally ready for its first adventure trip.

Under the carpet is a 60L water tank and a hidden storage space.

Finally the kitchen is complete.

Last pic is the drawer syetem installed.

Niel · Post by **Niel** » Sun Aug 02, 2009 9:54 pm

Jose, very nice and well done.

1 Question, is that beer for me

esajoda · Post by **esajoda** » Mon Aug 03, 2009 7:08 am

Thanks Niel.

I owe you a case if you take all the ideas I got from you. :) , when in Cape Town again.

barleigh · Post by **barleigh** » Fri Aug 08, 2014 4:29 pm

Inspiring stuff.
You have definitely given me some ideas for my spare time and cash for the rest of the year!
Thanks for sharing.

Post by **Haboob** » Mon Aug 11, 2014 3:30 pm

Very nice, neat and well done...

Thunder02 · Post by **Thunder02** » Mon Aug 11, 2014 3:36 pm

Very well done, like the way you've used the space.

CMK · Post by **CMK** » Thu Aug 28, 2014 7:55 am

I must say that this is well done! Im busy building a canopy for my d/cab Cruiser and it takes a lot more thinking and the correct execution to get it all correct.

Obelix and Dogmatix · Post by **Obelix and Dogmatix** » Thu Aug 28, 2014 8:25 am

Jose you lie!!

That is not an attempt!!!