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Old 02-11-2017, 05:43 PM   #1
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1965 26' Overlander
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Aluminum endcap

Today I finally started on my front endcap. This is 6 1/2 hrs!, only 12 more pieces to go!Click image for larger version

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Old 02-12-2017, 04:49 AM   #2
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Looks good, I used the same technique with wood door skins. The wood parts ended up needing steaming to make those compound bends. I too like the look better than the end caps.
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Old 02-12-2017, 05:51 AM   #3
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Nice!

What material are you using?
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Old 02-12-2017, 07:19 AM   #4
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I'm using 5052 .032 aluminum
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Old 02-26-2017, 04:15 PM   #5
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Getting closer... Olympics shaved, one more piece to go!Click image for larger version

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Old 06-29-2017, 08:08 AM   #6
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Aluminum endcap

About to embark on this project on my '60 24' Tradewind following your very helpful ideas. I know wood but not metal and it's not clear to me how to cut the aluminum sheet properly w/o damaging its edges. Eastwood makes an electric tool which seems to fit the need for cutting a clean line.

http://www.eastwood.com/electric-met...h6cRoCmiXw_wcB

What is typical for a project like this? You
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Old 06-29-2017, 09:45 AM   #7
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The Eastwood nippers

will do the trick, I use some just like them and they make great, clean cuts
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Old 06-30-2017, 04:53 PM   #8
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I had mine sheared at a Sheetmetal shop
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Old 07-01-2017, 06:55 AM   #9
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I should note though

that I sanded the edges with a table sander after I cut them with sheers. It worked beautifully
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Old 08-03-2017, 06:30 AM   #10
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Could you mix 5052 & 20-24 T3 and have the same ease of installation and finished look?
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Old 08-03-2017, 07:16 AM   #11
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I wouldn't

I wouldn't mix 5052 and 2024, the finishes will look different: the 2024 will be much shinier
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Old 08-03-2017, 07:24 AM   #12
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Aluminum endcap

Quote:
Originally Posted by DDickey View Post
I wouldn't mix 5052 and 2024, the finishes will look different: the 2024 will be much shinier


Thanks. That is good to know. I've stripped the factory Zolaton off the interior aluminum and will not repaint it. Am I correct the existing interior skin is 20-24 T3 or equivalent on this 60 Tradewind?
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Old 08-03-2017, 09:44 AM   #13
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Looks good!
-Assuming 20hrs for the project?
-You mentioned you had cut at a shop? On your end seam cut cuts would have a very slight concave due to the compound curve? Are the cut straight? Is the line perfect or are there minor "steps"?
- also for around your window did you just cut with hand shears ?
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Old 08-03-2017, 12:31 PM   #14
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End Cap Material

Quote:
Originally Posted by Bexar View Post
Thanks. That is good to know. I've stripped the factory Zolaton off the interior aluminum and will not repaint it. Am I correct the existing interior skin is 20-24 T3 or equivalent on this 60 Tradewind?
It's 2024
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Old 08-03-2017, 09:20 PM   #15
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Aluminum endcap

Quote:
Originally Posted by Swillv8 View Post
Looks good!
-Assuming 20hrs for the project?
-You mentioned you had cut at a shop? On your end seam cut cuts would have a very slight concave due to the compound curve? Are the cut straight? Is the line perfect or are there minor "steps"?
- also for around your window did you just cut with hand shears ?

Don't know what to expect time wise. Whatever it takes. This is a labor of love. I will not have a shop cut metal for me again. They used hand shears. Just used the right ones and made the cuts slowly and carefully. I was expecting them to use large metal shop tools for the cuts. If you refer to the very beginning of this long thread there is a discussion about the lack of need for cutting compound curves. All 11 panels are simple rectangles. And the only edges which will show is the center panels. Yes, just hand shears for cutting around the window.
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Old 08-06-2017, 08:43 AM   #16
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Shears

These Harbor Freight electric shears make great, clean cuts. I used them to cut my end cap, then I used a table sander to sand the visible edge. Sanding wasn't totally necessary, but it did make the edge a little nicer
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