geek49203 wrote:
The metal just seems to either be very heavy (18 gauge, kinda seems like a 1950's Caddy trunk) or needs a lot of support over the span (you just know someone is gonna sit on it?).
Mine's 24 gauge (prepainted roofing steel) and nobody has sat on it yet.
geek49203 wrote:
JD et al -- just make a foam core arrangement on this deck lid? Use the blue foam, bend to shape, and cover it w/ glass, then cover the underside, encasing the metal bits?
Just remember that styrofoam is (big surprise) styrene soluble. Styrene is the stuff in polyester resins that makes it thin enough to penetrate the fibers in the fiberglass, so you need to use epoxy resin or it will dissolve into a sticky glop, much like the dip in
Roger Rabbit. Also, use cloth rather than mat for your glass--two to four layers--and if you're careful/lucky all you'll need to do is fill in the pattern of the weave. You might not even need body putty; a couple/few passes of Featherfill (or similar catalyzed polyester primer) may be all you need. That, and lots of block sanding.
If I were doing mine again...nah, I'd do it the same way I did before. Milwaukee Jim used aluminum, which is fine too. This is an application where sheet metal is quickest and easiest and cheapest, and unless you make it Caddy-trunk-thick, probably lightest as well.