Rising Sun Member Forums  

Go Back   Rising Sun Member Forums > Toyota 4x4 > General Chit Chat

Reply
 
Thread Tools
  #1  
Old 04-18-2012, 02:57 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Davinci Wing Awning

Just a catchy name to get your attention.
I REALLY dig the foxwing awning, the price....not so much.
So, I also like to work on "inventions" that never seem to get beyond paper, so there you have the "davinci wing" awning.
Foxwing is patent pending, so in no way am I currently looking to produce something like this. It's really just a "hey, I have half that stuff lying around and I like making junk for fun" kind of project.

Here goes:

Since most of you have upgraded to synthetic winch line, bet you have a roller fairlead laying around, don't you?
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #2  
Old 04-18-2012, 02:58 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Chop it!

Take that old fairlead apart, and mount it up in the bandsaw and slice it right up next to where the vertical rollers are supported.

Wind up with this:
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #3  
Old 04-18-2012, 03:00 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Slice and dice

Now, you will have to clearance the upper portion a bit. This will likely be trail and error to get the right fit, so don't take too much off this yet.

You will also want to pop out the roller and mount that up in the bandsaw as well. Slice it into 4 EXACT pieces.

You will wind up with this:
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #4  
Old 04-18-2012, 03:05 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Sleeves

You have a stack of thin wall steel tubing laying around right?
Great! Cut 4 equal pieces about 3" long. Wait....did I remind you to measure your exact fairlead model for height? Nope? Okay, this is where the design gets interesting. At this point, you have to decide on whether your "sleeves" will be an inny or an outy. I'm leaning towards an inny...which means these will be inserts for the fly rods. This will allow the diameter of the aluminum rods to be as large as possible and still fit inside the height of the roller.

Now that you worked that out, clamp those 3" pieces up in your drill press and run a 1/4" drill through them about mid point.

Wind up with this:
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #5  
Old 04-18-2012, 03:10 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Burn it!

Now that you have resolved your particular design based on your fairlead and have cut your rod holders, grab that trusty welder.

Caution: Rollers are likely coated with nasty stuff you don't want to breathe while welding.

Weld each rod holder onto one section of the roller you sliced. You want to push the holder in enough to get a bead on both sides.

Wind up with this:
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #6  
Old 04-18-2012, 03:13 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Open poppy

Go ahead and open that sucker up. The top roller slice will open a full 270 degrees until it rests against the roller brace. This is where the fine clearancing takes place. Take your fly rod into consideration (in or out design) when shaving the final bits off the stop.

You should wind up with this:
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #7  
Old 04-18-2012, 03:28 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default

So now we have a nifty foundation, but the next step involves making some decisions. I don't want to sew too much on this project, so the frame I will build out of aluminum angle will need to fit the bag. This one looks like it will work nicely and it's 180cm long (about 6') http://www.ebags.com/product/athalon...ductid=1038281

Or maybe this one: http://www.ebags.com/product/athalon...ductid=1038283

The trick is finding one that the zipper goes all the way around enough to let the awning fold around.
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #8  
Old 04-18-2012, 04:00 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Framing

Now that we have our bag for the basis of design, I see that the bag is 74" long, so I will start with the frame at 72", but we may need to trim a tick off the end before it's all done.

Take some 1-1/2" aluminum angle and drill some mounting holes on the back side. Don't forget to avoid the "flange" on the other side of the winch roller support. Be sure to get these holes lined up top to bottom, as they will be the basis for securing this to the rack.

Note: You need to notch the aluminum to match your "stop" for the upper pivot.

You should wind up with this:
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #9  
Old 04-18-2012, 04:13 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Frame at length

The opposite end should be far simpler in design. While I dig how the poles snap in on the Foxwing, this one will likely just have a velcro band secured on the back side where the aluminum frame bolts together. We'll revisit that later.

Here's an overall shot:
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
  #10  
Old 04-18-2012, 04:28 PM
OilHammer's Avatar
OilHammer OilHammer is offline
Rising Sun Member
 
Join Date: Apr 2009
Location: Denver
Posts: 671
Default Fly rods

So for the purposes of the model, I'm drawing these as fitting inside the sleeves we welded to the fairlead slices. Really, it is probably the better design as it allows for some room for the material to go over the rod and not bind with the rod below. I've never seen a foxwing in person or even up close in photos, but I would guess this is what they did as well.

Cut four "rods" just shy of 6'. Drill 1/4" hole about an inch from the end of each one. Orient the holes you just drilled so they are top and bottom. Now take the non-drilled end and insert it into the sleeves. Mark the hole locations, drill, and then insert a 1/4" clevis pin. Obviously you will need to clearance these holes a tick to get it to go on cleanly.

I like the idea of being able to remove the "rods" easily, but at this point, I don't suppose it really matters unless one of them gets bent and you need to pull it out and toss it in the truck to get home.

You should be looking at something about like this:
Attached Images
 
__________________
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 stock
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
KD0PZL
Reply With Quote
Reply

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off


All times are GMT -6. The time now is 09:53 PM.


Powered by vBulletin® Version 3.7.1
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.