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Old 09-28-2008, 08:09 PM   #1
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How to Create a Door Drip Cap

I'm not sure if this is actually called a drip cap, but I need one of these badly. I know the suggested Aluminum for regular skin replacement is .032 2024-T3, but what do you suggest for this drip cap usage? The original drip cap is fairly lightweight but mine is creased and bent badly so i'm hoping to make it from new material. Any tips would be much appreciated.
Thanks!
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Old 09-28-2008, 08:43 PM   #2
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I would use the thickest material you can work with. I think .040" if you use 5052 or 6063. If you try it with 2024 I would use .032".

I'm not sure what the original was, but it may have been .025", which is why it gets bent so easily.

Start with cardboard to make a pattern. The shape where it meets the body will be a sigmoid shape, not an arc of a circle. Draw the point of contact with the body with a marker or masking tape. Make the pattern without the flange, you can add that when you transfer the pattern to metal.

Once you have the curve, tape it in place and step back about ten paces. Make sure the top of the eyebrow is horizontal, not pitched up or down. Make sure the door clears the outside edge.

Trace the pattern onto metal, and add 1" to the body side for a flange, and 1/4" to the outside for the upturned lip.

Turning the flange is a long and difficult process it you use a pair of flanging pliers, but it's doable.

Order enough material for two, you may decide the first one isn't good enough. The learning curve is fairly steep, the second one will be a work of art.

Take it slow and it will be one of the most satisfying things you will do to your Airstream.
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Old 09-29-2008, 03:43 PM   #3
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I'm taking the liberty of adding these names to the site in case future restorers need help and are searching these references: I call this item a "door drip cap" but found an old post from Rob Baker where he called it a "drip eyebrow lid" Either way, I have a sad one and I need to either buy one or make one. CaChing....
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Old 09-29-2008, 05:39 PM   #4
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That "eyebrow" was one of the coolest features; our '64 trailer had one. Seems things
changed a tad: here's what they gave us in '83.
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Old 09-29-2008, 05:47 PM   #5
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Quote:
Originally Posted by markdoane View Post
Take it slow and it will be one of the most satisfying things you will do to your Airstream.
Well done.:clap
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Old 09-29-2008, 06:02 PM   #6
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Quote:
Originally Posted by 1956Safari View Post
I'm not sure if this is actually called a drip cap, but I need one of these badly. I know the suggested Aluminum for regular skin replacement is .032 2024-T3, but what do you suggest for this drip cap usage? The original drip cap is fairly lightweight but mine is creased and bent badly so i'm hoping to make it from new material. Any tips would be much appreciated.
Thanks!
Attachment 68457
This is my drip cap for my 1955 Safari
http://www.airforums.com/forums/f36/...t-38289-3.html and http://www.airforums.com/forums/f36/...t-38289-4.html
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Old 09-29-2008, 06:17 PM   #7
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You can make the eyebrow very easily in my opinion. I have this on my list for the winter months. If you were to remove it, you will find that it is about 39 " long and the front edge is not curved, but straight The back edge has a fairly gentle arc. The tricky part is bending the flange that goes against the trailer. It is on the edge that is curved. It would take some time, but a hand break would slowly bend it over. The angle of the flange is what is important for it changes as it goes around the curve. Just drill the old one off, trace off of it and cut then bend. you can copy the rivet holes or make new ones. A strip of buthyl between it and the skin... 2 hour job with frequent beer breaks.
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Old 09-29-2008, 06:58 PM   #8
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Ok Frank, I'm buying enuff to make two. A 4'x2' sheet is Airplane Spruce's minimum, so if I don't screw up the first one, the second one is yours!
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Old 09-29-2008, 07:35 PM   #9
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I am honored by your offer. Make yours first and see how it goes. Toastie did an excellent job and if you are not, you should follow his thread closely. The bending of that flange is the tricky thing in that it is on a curve. You are stretching it slightly by doing it. The angle of the bend too, has a lot to do with creating that curve that makes it the eyebrow shape.
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Old 09-29-2008, 08:43 PM   #10
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Look at the great drip caps on the current pic. "Airstream 003".
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Old 03-17-2017, 10:38 AM   #11
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Seems like I saw a door "eyebrow" formed using a groove routed in a piece of plywood. Does anyone recall or have any info on that? Thanks in advance, JT
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