The final panels to build go on the sides of the bed over the fenders. Way back in Part #3 I made templates for these panels.

 

At that time, I wasn’t sure I would have enough room to connect the 2 panels over the fender. Some additional work showed that I could have this panel be a single piece. I transferred the pattern into a 2D drawing.

 

I also traced my paper pattern onto a sheet of thin plywood – around 3/32” (called doorskin here). I took that down to Michael’s place and laid it on the bedside body panel. I then found that the body curved slightly right at the back near the tail gate. The curvature was subtle enough that my paper pattern conformed easily but the plywood (and my panel) would not conform. Plus building a panel with that curvature would be difficult. The rest of the panel will be flat. 

 

So I shortened it by a little more than 1.5”. The new size in in green.

 

With the panel resized I also revised the plan for the form locations. You can see the form locations in between the two panels. I also drew in the strip locations. The form positions give me the ability to support each strip in at least 2 places.

 

Since these panels are flat, the forms are simple. I choose a height and cut each form to length.

 

Also these panels are shorter so I can remove my extension from the strong back.

 

Then I can mount the forms.

 

Past experience pays off. I predrilled holes in the end forms and added cleats to enable easier clamping later on. Now the strips go on.

 

I set the ash strips at each end.

 

And fill in the cherry strips.

 

Since the panel is flat the fender trim pieces curve in one direction only. With some time on my 2D drawing I have a wide ash board that gives me the first layer with no curved cuts. A straight edge guides my saw.

 

And the ash trim is installed.

 

A seal coat of epoxy goes on.

 

And the glass cloth with the fill coats.

After sanding and polishing I can start adding the trim. I start by sizing and locating the blanks.

 

I use my paper pattern to lay out the curves.

 

Now I can cut each piece to shape, round over the edges and sand them smooth. Then they get coated with epoxy.

 

I mask off the inside edges to help manage the squeeze out and epoxy the trim in place.

 

Once the epoxy sets I can take the panels off the forms.

 

And I am finally done with the strong back living on my table saw!!

 

The panels get taken outside for fiberglass and polyester resin. Outside is so much better with this stuff.

 

Since the panels are flat I can trim the excess with the bandsaw.

 

After that I smooth and epoxy the edges. After a final sanding to 400 grit they are done.

The smaller panels, simpler design, and previous experience all made these panels get built quickly. I’m guessing just over a month to build them.