The plan to make the bed side panels next is being postponed. I need to double check my template for the sides before I commit the design to a build. So – the tailgate panel build is next.
Michael provided a 3D scan of the fiberglass tailgate cover.
The file is of a surface with no thickness. That is all I need. You can see that the edges are ragged. The first step is to trim those edges. I have overall dimensions from Michael so I can know how much I have trimmed off. In order to trim the edges I need to set the cutting lines square to the orientation of the imported surface. A few measurements dial that in.
Now I can start to get cross section profiles. I start at the far side and then trim about 5 inches off and get another profile.
I repeat this until I have 9 profiles. The last 2 are a little less than 4 inches apart.
I then start over and create cross profiles.
I repeat this until I have 6 cross profiles.
I now have a set of curves that match the scanned image of the tailgate cover.
It’s hard to see from the image but the cover is a bit warped on one corner. This is not a surprise for an unsupported panel. I need a set of curves that are symmetric and that are positioned to support the strips in appropriate locations.
I only need new profiles for half of the tailgate. I can use them for both sides. You can see on the left edge of the image above the slight bit of warp.
I now have a map of form locations that matches the requirements of the strip layout.
The end of the process is to design the forms themselves. The strip plan is shown above the forms.
Once the second body panel comes off the forms I can mount these forms on the strong back.
Wow, this process along all others already posted, is something to be admired, and I do. You're doing all this highly technical work and taking it in stride. Cuidos to you Steve.
Thanks Jim, It's interesting - the body forms were set up by manual measurements (basically a manual 3D scan). The tailgate is a 3D scan from a camera. And the bed sides will likely be a template directly off the bed panels. 3 panel sets and 3 different ways to set them up.
How are you making those forms Steve? CNC? Just curious if you were parameterizing those vectors or working with them directly. In any case, awesome process 😎
I see some embellishment in your design for the panel. Inlay after the fact or incorporating it into the panel-making?
The process feels complicated when I start but many hours of preplanning gets it simplified for me. I I were to include my mental hours in my total hours the number should probably double! 😁
Ken - Yes, I'll be using the CNC to cut the forms. If I didn't have the CNC I would print the shape, bandsaw and sand to the line. I worked with the vectors directly for the first set of curves and then created B-spline curves for the final shapes. I don't see the need, but I could use the B-spline curves to sweep a solid body model of the tailgate. The trim pattern will surround a VW logo emblem.
