Canopy Build.... The start of my projects.

Legendary · Post by **Legendary** » Mon Jan 14, 2013 8:17 am

So I have been contemplating the build of my canopy for some time now and that time has finally arrived.

I was planning to cut weld and and build this myself, however I probably would have spent more money cutting and welding and cutting and re-welding the same piece over and over again.

So I went on the hunt for someone to help with the welding and to suppliy the required materials....

I FOUND THEM......

I am not going to give prices at the moment as we are doing the canopy piece meal (bit by bit) as I am getting ideas as we go along.

So I will be updating this forum with pictures and notes on the build and would really like some comments on going forward.

Pics to follow.

Post by **CasKru** » Mon Jan 14, 2013 9:48 am

Looking forward to the pictures to follow and the end result

Legendary · Post by **Legendary** » Mon Jan 14, 2013 10:12 am

Pictures so far...

Legendary · Post by **Legendary** » Mon Jan 14, 2013 10:13 am

[quote="CasKru"]Looking forward to the pictures to follow and the end result[/quote]

Pictures as requested....

Frost · Post by **Frost** » Mon Jan 14, 2013 10:30 am

Hey bud,

Looks good so far and your ideas are great. Looking forward to seeing the progress!

Thunder02 · Post by **Thunder02** » Mon Jan 14, 2013 12:20 pm

Still between buying or building,so your build might give me motivation to build

MOFASA · Post by **MOFASA** » Mon Jan 14, 2013 12:34 pm

Thunder02 wrote:Still between buying or building,so your build might give me motivation to build

It is sooooooo much cheaper to build..... about 1 third of the price in total...

That should be motivation enough.....

ChrisF · Post by **ChrisF** » Mon Jan 14, 2013 2:23 pm

sal die een dop hou :)

self lus vir speel ...

Thunder02 · Post by **Thunder02** » Mon Jan 14, 2013 2:33 pm

MOFASA wrote:
Thunder02 wrote:Still between buying or building,so your build might give me motivation to build

It is sooooooo much cheaper to build..... about 1 third of the price in total...
That should be motivation enough.....

Time has always been a problem :roll:

WayneSchalk · Post by **WayneSchalk** » Mon Jan 14, 2013 3:18 pm

Ek word ook nou so oortuig om weer een te bou, ek dink die 2de ronte sal makliker gaan, bitjie nuwe ideas gebruik, ek hou die een dop

louis fourie · Post by **louis fourie** » Mon Jan 14, 2013 6:35 pm

Ek kyk en leer - lyk goed

Froll · Post by **Froll** » Mon Jan 14, 2013 9:04 pm

Looking good. I also want to build one so I will watch this one as well as some others to get some tips before I start on one for myself.

JJBotes · Post by **JJBotes** » Mon Jan 14, 2013 9:22 pm

You have more guts than me !! Good luck and enjoy . . .
(sub)

Legendary · Post by **Legendary** » Tue Jan 15, 2013 6:58 am

Ok so more work was done yesterday, the frame is coming together nicely.

I have decided to go for two doors on the one side and one long door on the other, pretty much what everyone else does, but it makes sense to me.

I am a little concerned though as I have the tail door quite big which means there is not much space on the side of the door to mount gas bottle holders on the back, but I will make plan even if they stick out the side a bit.

I will post some more pictures in an hour or two.

WayneSchalk · Post by **WayneSchalk** » Tue Jan 15, 2013 7:13 am

Legendary wrote:Ok so more work was done yesterday, the frame is coming together nicely.

I have decided to go for two doors on the one side and one long door on the other, pretty much what everyone else does, but it makes sense to me.

I am a little concerned though as I have the tail door quite big which means there is not much space on the side of the door to mount gas bottle holders on the back, but I will make plan even if they stick out the side a bit.

I will post some more pictures in an hour or two.

Rob with the canopy I had on my KZ I found I would prefer a full door at the back, reason being the fridge slide does not pass under the tri angle so you end up moving it to the middle.

you can always put the gas bottle on the roof rack. But that is me.

Update with some pics please

Legendary · Post by **Legendary** » Tue Jan 15, 2013 7:23 am

Thanks Wayne for the input, I however don't really like the idea of a fridge as i will probably run my battery flat.
I have a mate that builds special cooler boxes for transporting blood and vaccines into Africa where there is no electricity and these can keep ice whole for up to 7 days depending on the amount of times you keep opening it.

But I did have a concern about the opening being big enough but I suppose this is how you learn....

WayneSchalk · Post by **WayneSchalk** » Tue Jan 15, 2013 7:28 am

Legendary wrote:Thanks Wayne for the input, I however don't really like the idea of a fridge as i will probably run my battery flat.
I have a mate that builds special cooler boxes for transporting blood and vaccines into Africa where there is no electricity and these can keep ice whole for up to 7 days depending on the amount of times you keep opening it.

But I did have a concern about the opening being big enough but I suppose this is how you learn....

I'll dig for a picture of the 2 canopies I had and post it for you.

WayneSchalk · Post by **WayneSchalk** » Tue Jan 15, 2013 7:30 am

Here is the one I built with my old man

WayneSchalk · Post by **WayneSchalk** » Tue Jan 15, 2013 7:52 am

En die een van Gomad

Legendary · Post by **Legendary** » Tue Jan 15, 2013 9:19 am

Thanks, I have designed mine pretty much the same way, I measured the triangular shape at the back against the first eye fot the tourniquet cover and I see yours is the same.

I will post pics in about 30 minutes.

Legendary · Post by **Legendary** » Tue Jan 15, 2013 10:48 am

Right here are the pics i have so far.

Thunder02 · Post by **Thunder02** » Tue Jan 15, 2013 12:13 pm

Rob,the bottom cross bar on the tailgate side,are you going to cut it out or keep that solid?

WayneSchalk · Post by **WayneSchalk** » Tue Jan 15, 2013 12:17 pm

Are you going to paint, powder coat or galvanize?

Donkey · Post by **Donkey** » Tue Jan 15, 2013 12:20 pm

Thunder02 wrote:
MOFASA wrote:
Thunder02 wrote:Still between buying or building,so your build might give me motivation to build

It is sooooooo much cheaper to build..... about 1 third of the price in total...
That should be motivation enough.....
Time has always been a problem:roll:

Get a cheap watch so long

Legendary · Post by **Legendary** » Tue Jan 15, 2013 12:42 pm

The cross bar over the tailgate will be cut, well that is the idea, unless someone has a better idea?

It will be polished and primed and sprayed silver to match the checkered plate.

Legendary · Post by **Legendary** » Tue Jan 15, 2013 6:37 pm

Right, update so far, the frame is complete, the doors have been welded together and attached to the frame.

Busy cleaning up all the welding edges and putting the door stops in place.

Trying to figure out which locking mechanisms to use now, as I am trying to be very money concious and the Pressure lever locks are not the cheapest.

I have seen something but want to go and check them out first before I say anything.

Any ideas

Thunder02 · Post by **Thunder02** » Tue Jan 15, 2013 6:49 pm

Go have a look on 4x4direct locks for sale there at a good price

Legendary · Post by **Legendary** » Wed Jan 16, 2013 9:15 am

Hi Neil

I have had a look on 4x4Direct at the pressure locks, however at R600.00 it's a bit expensive even though you get 10 of them.

I would require 8 for my canopy and having a spare is ideal, but at that price, it's almost the amount I paid for the 25x25 mild steel for the ENTIRE canopy.

I have been looking at the traditional canopy handle and came across what they call the "Pop-up T Handle" so I will be getting prices on those during the course of the day.

Will let you know and see if I can find a picture and post it.

Willem01 · Post by **Willem01** » Wed Jan 16, 2013 10:04 am

You can really invest in those pressure locks at 4x4 direct, I sourced some local suppliers SACC in Pta and they charge double the amount for exactly the same lock..

4x4Maniac · Post by **4x4Maniac** » Wed Jan 16, 2013 6:48 pm

Rob looking good so far. Are you going to fit a sliding window to the front and normal window to the rear? Also a nice idea is to put either cross members at the top in case you want to put a rooftop onto it or roofrack, just get the correct sizes as otherwise it will make fitment difficult.

I've also seen the frames of the doors made easily through sikaflex and pop rivets, so no welding.

And lastly I would highly recommend those locks from 4x4Direct, it is such a great investment!

That's m2cw.

Thunder02 · Post by **Thunder02** » Wed Jan 16, 2013 7:36 pm

And "no" Rob we don't work for 4x4 Direct,you will not be sorry

Legendary · Post by **Legendary** » Wed Jan 16, 2013 9:55 pm

Thanks Werner for the comments.

I don't think I will be putting windows on the canopy, it was a tough decision to make, but reason being I don't like the idea of packing all my "expensive camping" stuff in the back for any Tom Dick & Harry to have peek and decide that they need one of them.

Also I will be building a drawer system, once that's in place and the cooler box and everything else (wife's suitcase) I wouldn't be able to see through the windows anyway so it would defeat the purpose, and it would put my costs of build up a bit.

I am planning to add a roof rack to the top so that I can fit a roof top tent at some point.

I do like the pressure locks on 4x4 Direct but will have to see which root I take when I get the price on the others I have in mind.

I have taken some updated photos and will be posting them in the morning so stay tuned, I am hopping to be finished by the weekend.........

Thunder02 · Post by **Thunder02** » Thu Jan 17, 2013 6:56 am

standing by

Legendary · Post by **Legendary** » Thu Jan 17, 2013 8:11 am

ok updated pics time....

the frame is done and we have started cutting some of the panels, not quite sure how far we are going to get but might be finished by the weekend.

Legendary · Post by **Legendary** » Sun Jan 20, 2013 11:49 am

So....

we had a little delay in recieving the Aluminuim plating to cover my canopy!!! :evil:

However this should arrive Monday

I did however put the canopy on my bakkie to check that all is still in order and that everything is fitting into place.

You will see that i have made the canopy higher than the roof of the cab, this is becaue i aklso have a roof rack that fits the cab, so i might as well use the extra space.

smokintyres · Post by **smokintyres** » Sun Jan 20, 2013 12:05 pm

Great job so far!

What kind of hinges did you use on the doors? Or was it mentioned in a previous post and I just missed it?

Legendary · Post by **Legendary** » Sun Jan 20, 2013 12:29 pm

I have used quite a big mild steel type hinge, that I welded to the frame itself.

Nothing special really.

Oupa Stig · Post by **Oupa Stig** » Sun Jan 20, 2013 12:39 pm

Years ago I built my own steel frame alu canopy without any reference to other canopies, having only seen one or 2 in passing on the street. As my truck is a workhorse I wanted to be able to open a door with one hand while carrying toolbox etc in other, so used normal old fashioned canopy hanldles which mount in the center of the door. They are too heavy, and impossible to keep the rods from rattling. Now that I've seen the more modern designs my next canopy will definately use those 'pressure' locks. They are not that much more pricey for the benifits they add.

smokintyres · Post by **smokintyres** » Sun Jan 20, 2013 12:52 pm

Legendary wrote:I have used quite a big mild steel type hinge, that I welded to the frame itself.

Nothing special really.

Thought so. Same here

Not as good looking as the aluminium bolt-on ones, but easily removable in the open position; very happy with my choice so far

Just remember to grease them regularly.

Legendary · Post by **Legendary** » Sun Jan 20, 2013 1:34 pm

Mickey, I was looking at the pressure locks however I do need to keep my costs down, I have some ideas on how to stop the rattling of the arms, so will have to see what happens.

Things can always change...

Legendary · Post by **Legendary** » Sun Jan 20, 2013 1:36 pm

Thanks for the tip, I will make sure they stayed greased up....

smokintyres · Post by **smokintyres** » Sun Jan 20, 2013 1:58 pm

Legendary wrote:Mickey, I was looking at the pressure locks however I do need to keep my costs down, I have some ideas on how to stop the rattling of the arms, so will have to see what happens.

Things can always change...

Just an idea: If you need to keep cost down I can recommend the locks usually used for tralies:

A 40mm lock fits perfectly through the larger type lock and as shown, you won't have the lock dangling and causing ugly scratches. Also no rattling

If you have already purchased the fiber glass canopy type locks: some polystyrene (cold room insulation material) stuck behind the bars gets rid of some of the rattles almost permanently.

Frost · Post by **Frost** » Sun Jan 20, 2013 2:13 pm

Looks good bud!

I am definitely next in line. Smaak to see the finished shell when its done, as weve talked about I would like to see the sealing of the doors and the inside of the doors idea, coz im skeeming of having the basic frame built at the same time for mounting the goodies on the inside. Not too keen on wood because its extra weight but definitely easier fo mounting stuff onto and changing it later? Ideas welcome..

So far by the sounds of things much cheaper than getting the ready made deal... and you can add on as the salery allows.

Keep the pics coming!

Frost · Post by **Frost** » Sun Jan 20, 2013 2:22 pm

And let us know of the total weight of the shell?

Oupa Stig · Post by **Oupa Stig** » Sun Jan 20, 2013 4:06 pm

The foam rubber behind the rods sound like a good idea.... One of those 'now why didn't I think of that....'
Waterproofing is a whole different kettle of fish, and my own completely over - engineered system does not work. In hindsight have realised I could have saved myself a lot of work and weight... A wise man learns from his mistakes, but a genius learns from other people's mistakes.

Legendary · Post by **Legendary** » Sun Jan 20, 2013 10:00 pm

This is why I love this forum, I would not have thought of more than half the stuff I've seen and read.

Thanks for all the tips, please keep them coming.....

I like the idea of wood, I think it would be less noisy/rattle less than more metal, also she it comes to mounting stuff I think it would be easier.

But the "cupboard" thing will only happen later, lots of time and a good couple of beers (wisdom juice) to flow before then.

Legendary · Post by **Legendary** » Wed Jan 23, 2013 9:09 pm

So we got stock of the alu and started cutting and fitting today, the roof is on and the front panel, really starting to look good now.

Manged to do one small door as well.

I will post picks in the morning for all to see.

4x4Maniac · Post by **4x4Maniac** » Wed Jan 23, 2013 10:17 pm

Legendary wrote:So we got stock of the alu and started cutting and fitting today, the roof is on and the front panel, really starting to look good now.

Manged to do one small door as well.

I will post picks in the morning for all to see.

Willem01 · Post by **Willem01** » Wed Jan 23, 2013 10:38 pm

Dit lyk goed so ver

...nou wag ons vir die res van die pics...

Legendary · Post by **Legendary** » Thu Jan 24, 2013 11:35 am

Here are some updated pictures.................

not going to add the locks and gas shocks as yet, but i will get there soon.

should have the canopy on the bakkie by tomorrow afternoon.

Please comment on what you think so far......

Revo · Post by **Revo** » Thu Jan 24, 2013 2:38 pm

Rob, dit lyk baie netjies. Jy het seker 2 sheets alluminium nodig vir die projek? Watter dikte het jy gebruik?

Froll · Post by **Froll** » Thu Jan 24, 2013 9:08 pm

Looking good so far, waiting for the next pics.

skilliefs · Post by **skilliefs** » Fri Jan 25, 2013 12:03 pm

Ek is nuut op die forum, ek wil self so canopy projek begin bou, watter dikte aluminium gebruik jy? Ek sal nie daardie "Pop-up T Handle" aanbeveel nie, ons het self so een op die canopy gehad, en as hy eers vasit, dan kry jy hom nie uit nie, ek vermoed dis die stof wat dit veroorsaak. Ek het self van daai pressure locks by 4x4direct bestel, hulle se almal gebruik die selfde sleutel as jy die stel van 10 koop.

TOYODA · Post by **TOYODA** » Sat Jan 26, 2013 9:23 am

skilliefs wrote: Ek het self van daai pressure locks by 4x4direct bestel, hulle se almal gebruik die selfde sleutel as jy die stel van 10 koop.

Ek het 'n stel van 10 gekoop en kan bevestig dat al 10 dieselfde sleutel gebruik.

MOFASA · Post by **MOFASA** » Mon Jan 28, 2013 1:24 pm

What thickness alu plate did you use??

Is your canopy on your van yet??

smokintyres · Post by **smokintyres** » Mon Jan 28, 2013 2:16 pm

MOFASA wrote:What thickness alu plate did you use??

Is your canopy on your van yet??

Johno you beat me to it: Where's the update? Any progress Rob?

niclemaitre · Post by **niclemaitre** » Mon Jan 28, 2013 2:33 pm

Our you can buy the pressure locks from MacNaughtans, and all the locks will be keyed the same, but keep in mind, ALL the locks are keyed the same so you can open locks on anyone's canopy...

Post by **Haboob** » Mon Jan 28, 2013 8:18 pm

Why do you open the doors downwards? Is this to use as a table? When opened you cannot get anything inside the vehicle while the door is being used as a table, as you are too far from everything, & cannot fold it further down as it is laden.
If they open upwards, they give shade next to the vehicle in the summer sun & protect you from the rain if it is raining (rain falls onto the door & runs off behind you...the door must be angled slightly down for best results...this gives more protection from the sun & rain). Just my 2cw

Legendary · Post by **Legendary** » Tue Jan 29, 2013 12:46 pm

Hi All

Sorry I have been away for the last couple of day on a fishing trip and have not had much signal to post replies. (Awesome trip by the way

)

So I will reply to everyone’s post.

Revo: I used pretty much 2 full sheets of the cladding, with a small piece to spare, thickness is about 1.2mm if I am not mistaken.

Skilliefs: I appreciate the advice on the locks, I am looking at purchasing the pressure locks from 4x4Direct, just got to wait a little time as I need to get some more cash together.

Johno: I put the canopy on the van this morning to check what i am going to do with the tail gate side of things, (you will see the picture below) as i want the door to hang slightly over the tail gate to provide a locking mechanism. Otherwise the can just open the tail gate and grab whatever they want. The rear door should be finished today. :razz:

Haboob: Thanks for the advice, the two doors that open downwards will be used as tables for the "kitchen" environment, (still to be built). The long door on the other side will be for access to the main of the bin. The small downward open doors will be on a "chain mechanism to keep it level, however i will be able to remove the chain so that it can go all the way down for access to certain things.

(I hope it works)

I hope that answers most of the questions and that i have missed anything out....

Photos to follow, just need to sort them out.

Legendary · Post by **Legendary** » Tue Jan 29, 2013 1:03 pm

Ok, so here are the photos.....