Saturday 18 January 2014

Tonneau - side doors

I'm working upwards now - if the roof doesn't happen I still need a way to enclose the car to stop it turning into a bathtub and filling with water. I'm going to keep things simple and build a tonneau - a four part design, side 'doors' and then covers over the top connected with zips.

Inspiration - woven shower curtain fabric makes a much better pattern material & only a fiver for 2m square. The datum is a string running from the windscreen bracket back around the roll bar sides:
Hindsight - The leading edge might do with some more fabric here and run right up to the windscreen bracket, especially if the mounting clips will sit behind the dash face.

Offside door complete - I have some heavy duty zips along the top edge for attaching other parts and simple bias tape edging to keep everything looking tidy. I'm intending to fit the doors completely first then measure for the rest of the cover - that should compensate for any errors/inaccuracy in making up each part.

Plenty of googling for videos on sewing & especially bias tape, its good stuff though - means I only need a hem along the straight zip edge - and gives a good finish even on curves:

On the inside no lining, but some reenforcement on the corners where it will be attached to the car:

Both sides complete & pretty much the same shape & stitching (on the outside) is presentable. Working with fabric is difficult 'everything' moves all the time but I think its turning out ok:


Tomorrow I intend having a go at fitting them - the plan is lift-the-dot fasteners so there is no way they can get blown off; the trick will be installing the fasteners to miss chassis tubes & get the right tension on the fabric panels.

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