You've made ya bed now weld it!
As I just mentioned I decided to see if I could get the panels made to make a whole new bed. I wanted to do a few custom tricks to it that entailed some new stake bed pockets so I enquired at a local metal fabrication shop about more work and even though they are a very busy big manufacturer they were more than happy to help me out and said they would be quite a while before they would be done I was well happy with the lads coffee jar price they wanted.
I just got on with what I could while they were being fabbed up.
Well they were finally done and what a superb job, they even cnc'd the square bolt holes for me, which I was going to drill and file ;o) The bed consisted of 2 side panels a mirror image of each other, with square holes and angled top edge, a length of 30mm tube for the top roll and some stake bed pockets and a couple of square panels for the lower edge.
I started with the rolled edge, to give them some rigidity, simply clamping them and welding
I really was determined not to warp these panels with my eagerness to get the finished. I would tack one end then go to the far end and do one there then the middle then the first end and so on until both sides were seam welded.
I had got some rolled edges for the stake pockets but only had 2 and I needed 4 so I set about rolling the bottoms of the front ones myself, quite an easy job again just a little time consuming
I also had to make the angle for the top of the stake pockets to fit up to the top angled edge of the side panels. I made a would jig ha ha if you can call it such just three bits of wood cut at the desired angle and nailed to some worktop. I then just cut the end as needed and hammered away. Not the most perfect job but good enough. With foresight I should of got the fab shop to of done them for me, but it is to late now.
I started to rosebud weld them but it was very time consuming and was thwart with danger of warping the panels which I didn't want. I lay awake that night as I do every night thinking about the task ahead and what was the best way to do it... I came up with a spot welder to save the day.
Dead easy spot weld the stake pockets on and the lower panels and that would take all of an hour eh. So I hired one from HSS. real efficient firm, but boy was this machine crap or what. I did a test piece and it fell apart so I upped the power and timer to full and ahh haa it worked. Great so I did a couple and tapped them with a hammer and clatter the fukkers fell off ???? Arghhhh So I tried again but doing the weld twice... and it held. But as I did more the machine seemed to just get weaker and weaker??? I persevered for a few hours and then just took the thing back. And plug/rosebud welded them in the end just in 4 corners and hope the spot welds I did hold. What a waste that was and the heat created by the spot welder warped the panels in the end aswell twat!!
Though every angle and measurement measures the same the front panel would not fit?? I just marked it and cut it off and will see to that later.
You can just see the gap I need to sort on the front panel here.
The tail gate was fitted that was easier to say than do, I had to transfer the holes already in the mounting crossmember out onto the stake bed pockets that covered the holes "Hum?" with mucho head scratching and marking I finally got the drilled and it fits a treat. The rolled edges look cool with teardrops welded to the edges and the rolled bottoms of the stake pockets clean the bed up ace I think.
Maybe that is why I am so happy now, I finally have one of them real Oak beds I have so admired in the past yeah me Holmsey with an Oak bed who would of thought it eh! I will polish all the stainless runners and bolts and rear edge and should look real class.
Not over enthusiastic about the Pro's Pick hidden rear catches, they work Ok but are more show than go. See how the tailgate fits perfect hey I am getting some things right at last.
Not sure on this one? This is the supplied rubber mounting pad and I cant see any other place it can fit. I was making some hard wood spacers I still might yet, but this is factory.
Another view of the tailgate hinge and rolled edges just the wings to mount.. not looking forward to that task.
Well as you can see I managed it, only have this photo of them finished well the inner bolts that hold them on finished. I bolted the running boards to the rear wings, jacked them one into position measuring umpty dumpty amount of times until I was 100% happy with the fit and angle, then marked the holes and went for it.. the double neigh treble checked and did the other side.. I am well chuffed they look and measure perfect at last!!
Then I started the LPG fitting AGAIN!!! Not sure why this board has a hole and a shaped gap?? And its painted? I may have to leave the hole so people can ask me what's the hole for mate, and I will say cant you guess and walk off ;o) or I could weld it up and get it painted again eh!! Whaaa Whaaa.
I had to drill out a hole big enough for the LPG filler point and this time it fits much better.
I am sitting the cage on rubber and bolt it through the wood and also at the sides to the bed.
I made up two 3/8ths mounting pads for the sides which I have now welded to the bed and the frame bolts to that with 8.8 bolts
The tanks fitting is now done, I had to just drill a small hole for the plastic coated copper hard pipe that supplies the LPG to the engine bay. Well that's about it so far September the 3rd 2007.
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I am going to do a new section that deals with the LPG fitting, hopefully this will help anyone who would like to use this fuel but thinks it is a black art or just not to sure what the job entails.
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