The Frankenstein Build! LT/Expo/Trail rig..and BS

You can always bring frank over here and we'll show you some good ole fashion southern wheeling

 

haha i wish! DD Frank in St louis would be a riot. But id hate to burn through all the rubber on the MTRKs in st louis..haha

 

Looks really good! Still trying to wrap my head around how it works though. haha

 

im in the middle of making the write up Be about 30 more minutes and you'll see!

 

25k miles on my DD with mtrs on them. About 1/3 life left, you'll be good

 

yea..now if i could justify 10mpg...haha or less really..

 

Since it got hot here it seems like my mtr's are melting away... they don't seem to like hot pavement at all lol

 

HA! i believe that!

I noticed a big chink missing from one of mine..and a tire plug...which i know i didn't put in. Did you plug it jon? @45acp

 

Tire plug?? Hell no. I never wheeled it hard enough. Are you sure that wasn't after your BJ failure? Or maybe a scrape or some shit that looks like a plug?

 

I didn't think you did..

No the tire that took the worst hit is on my spare now and is fine the tire shop said. The plug is on the passenger rear..or it looks like one..

 

Okay, big update time!

As you all know by now i build a new bed rack plus i did a bit of a refresher on the front end as well!

The new bed rack came around purely because the old one was just too tall. I mean, it wasn't that bad. But for as fast as i wanted to drive and terrain i want to drive. It just made Frank too tippy. Lowering the rack was the obvious solution. But come on. We all still need to pack the truck up too. And i like using the extra annex room with my tent too occasionally, so i needed it to move up and down.

I spent about 3 months thinking about how i was going to do it and finally had enough ideas to give it a try!

I started with 1.25'' and 1.5'' square tubing. I went square because bending round wouldn't have let me get a perfect right angle. In retrospect, i should have just got round tubing for the support legs. Which is probably the main thing id do different if i do it again, and probably will change that later.

New Bed Rack.jpg by Monte Nickles Photos, on Flickr

It took a lot of effort to make the 1.25'' slide into the 1.5'' since square tubing has a seam on the inside so you have to carve that out of the 1.25''...round doesn't have this if found out so would have saved me a shit load of time.

New Bed Rack-2.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-3.jpg by Monte Nickles Photos, on Flickr

But i made them slide just fine.

https://youtu.be/difj8aAQSxw

I then drill holes very precisely to line them all up. I again, fucked up here on accident. made the holes 13.5'' apart which screwed up which lift supports i was going to use that were 13'' travel and 60lbs of lift.

New Bed Rack-6.jpg by Monte Nickles Photos, on Flickr

this is the layout i used for pins

New Bed Rack-7.jpg by Monte Nickles Photos, on Flickr

i used a spring loaded pin on the driver side legs in addition to the trailer pins. I only did this on one side for a very simple reason. I wanted to be able to operate the bed rack by myself. Can't do that with spring loaded pins on both sides. My arms are long but not that long

New Bed Rack-9.jpg by Monte Nickles Photos, on Flickr

Passenger side just gets trailer pins. 3/8'' and i sleeved all the trailer pins.

New Bed Rack-10.jpg by Monte Nickles Photos, on Flickr

Welded in the pins and sleeves

New Bed Rack-11.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-12.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-13.jpg by Monte Nickles Photos, on Flickr

Then i made some feet out of 3/16"x1.25 strap

New Bed Rack-16.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-17.jpg by Monte Nickles Photos, on Flickr

i placed the legs right next to the last ridge in the bed and we figured out the width for the top tubes. 55.5'' i believe.

New Bed Rack-14.jpg by Monte Nickles Photos, on Flickr

Welded it on and here it is up

New Bed Rack-18.jpg by Monte Nickles Photos, on Flickr

and down.

New Bed Rack-19.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-20.jpg by Monte Nickles Photos, on Flickr

Im liking the height!

New Bed Rack-21.jpg by Monte Nickles Photos, on Flickr

Then there was another screw up. Both my brothers and my fault. He had been helping me which was super fun and cool and id had him cut the upper cross bars. He had literially cut two perfectly 55.5''. BUT when he went to cut the 1.5'' C cut out of the ends, he grabbed the scraped 53'' piece we had left over for the rear bar. I didn't check it and slapped it on the legs and burned it in!

Wasn't untill i set it down next to the front one i realized it was short lol So i patched in some tube to make it right.

New Bed Rack-22.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-23.jpg by Monte Nickles Photos, on Flickr

Then i started the side lift mechanism. I used 1/4'' angle iron, 1/8'' was too weak, on top of the square tubing and a weld on hinge on the passenger side. Then got some 2000lb double locking pull levers to hold it down.

New Bed Rack-25.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-27.jpg by Monte Nickles Photos, on Flickr

I think put some 1/8'' angle on the back side on both ends to help it stay where i wanted it. This is another thing id change, probably should have just got some 1/4'' C channel.

New Bed Rack-24.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-26.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-28.jpg by Monte Nickles Photos, on Flickr

Then i started mounting the lift supports. Due to my early fuck up i had to make some weird mounts. Not a clean as i had originally planned..but it works. these strust are 80lbs lifting force and 14.5'' travel and won't collapse down below the crossbars like id wanted originally.

New Bed Rack-29.jpg by Monte Nickles Photos, on Flickr

Fronts lower are parallel and the rears got stacked ontop of the leg mounts to sit ontop of a ridge.

New Bed Rack-30.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-31.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-32.jpg by Monte Nickles Photos, on Flickr

At this point i can't believe how freaking hard the struts are to pull down. Like...way way hard. In fact im still not happy with how hard they are. But hopefully they will get easier over time.

Then i started the tent mount cross bars. I would once again sleeve one side to allow it to extend as one side of the tent lifted. And i put bullet hinges inside the tubes.

New Bed Rack-42.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-41.jpg by Monte Nickles Photos, on Flickr

Hinges on the other half

New Bed Rack-43.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-44.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-45.jpg by Monte Nickles Photos, on Flickr

Now the reason i put the hinges inside the tube was for this. So it buts up against the angle iron. Then i just cut off the other side a bit so it bends that particular direction. So for the front i cut off the top part and the rear i cut off the bottom part.

New Bed Rack-46.jpg by Monte Nickles Photos, on Flickr


And the sleeve part

New Bed Rack-49.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-50.jpg by Monte Nickles Photos, on Flickr

Front part gets the sleeve since it lifts last.

New Bed Rack-47.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-48.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-51.jpg by Monte Nickles Photos, on Flickr

And how i cut it to allow it to move

New Bed Rack-52.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-53.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-54.jpg by Monte Nickles Photos, on Flickr

It works!

New Bed Rack-55.jpg by Monte Nickles Photos, on Flickr

This is why i sleeved it. It moves, not a ton, but enough.

New Bed Rack-56.jpg by Monte Nickles Photos, on Flickr

New Bed Rack-57.jpg by Monte Nickles Photos, on Flickr

To make sure it always goes back in i put some spring on it and made some butt plates for the tube to meet

New Bed Rack-58.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-59.jpg by Monte Nickles Photos, on Flickr

Added the last cross bars that the tent actually bolts too

New Bed Rack-60.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-61.jpg by Monte Nickles Photos, on Flickr

tested it out

New Bed Rack-62.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-63.jpg by Monte Nickles Photos, on Flickr
Bed Rack by Monte Nickles Photos, on Flickr
Bed Rack 2 by Monte Nickles Photos, on Flickr
Bed Rack 3 by Monte Nickles Photos, on Flickr

It works. For the most part. It isn't perfect, i won't lie. the only part that works unbelievably awesome is the side lift. The rest, not supper easy to do alone. Least not as easy as id like. And its even harder to get down. I basically have to stand on it. But the it goes down just fine. Its also pretty richety when all the way up. I think i should have used 1.75'' round tubing for the outer and 1.5'' round for the inner. Which i think i might do later down the road. But for the most part, im pretty happy it works!

Next i got some 3/4'' round bar and made some handles to help push and pull it up and down. They do help a lot. My dad was home for just a little bit and came over to help torch it and bend it. Sorry i forgot my camera for these next two photos..

New Bed Rack-2.jpg by Monte Nickles Photos, on Flickr
New Bed Rack.jpg by Monte Nickles Photos, on Flickr

Made two for each side and two for the back that are longer.

New Bed Rack-72.jpg by Monte Nickles Photos, on Flickr

Then welded them on!

New Bed Rack-73.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-75.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-74.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-76.jpg by Monte Nickles Photos, on Flickr

Then i welded up everything else and put the tent back on.

But i still had other things to do. One of which was get my skid back on. I just decided to put the stock mount i ripped off back on for the time being. Needed straightening first though...lol

New Bed Rack-33.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-34.jpg by Monte Nickles Photos, on Flickr

welded it back on then realized i had an issue with the skid..again. My LCAs would hit it.

New Bed Rack-37.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-38.jpg by Monte Nickles Photos, on Flickr

so whipped out Jons favorite tool and cut off the corners.

New Bed Rack-40.jpg by Monte Nickles Photos, on Flickr

Can't get mad at RAT productions or whatever. Was like the first skid he ever made and i got it killer cheap..and actually has taken a lot of abuse..

New Bed Rack-39.jpg by Monte Nickles Photos, on Flickr

I also got some 16'' 700lb coils. Since i can't run flat bottom spring perches i was worried about the block height of the 18'' coils. didn't want to use them as bumps. Plus they were precomressed a good 1.5-2'' which gave me like barely an inch of down travel. With the new coil, only hav .75'' preload and im at the EXACT height as my old eibachs and 5100s. 14.5'' at the skid. Looks way better too and drives a bit nicer i think.

New Bed Rack-35.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-36.jpg by Monte Nickles Photos, on Flickr

Next i got come CBI ditch light brackets..but not for some lil LED shit. I put my HID Hellas on there haven't wired them up but i know they will work awesome. The Brackets are top quality and easy install too. They are 1/4'' steel if anyone is curious.

New Bed Rack-64.jpg by Monte Nickles Photos, on Flickr

They go right on top of the hood hinge. CBI provides new longer bolts

New Bed Rack-65.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-66.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-67.jpg by Monte Nickles Photos, on Flickr

Some dirt in there....

New Bed Rack-68.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-69.jpg by Monte Nickles Photos, on Flickr

You do have to cut the plastic cowling. But not much and thats it really.

New Bed Rack-70.jpg by Monte Nickles Photos, on Flickr

On top of that @552Jrider sent me some clear corners he had just lying around. For FREE. Thanks man! Wow they look good..

New Bed Rack-90.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-88.jpg by Monte Nickles Photos, on Flickr

The hellas don't look great..but not bad. I ordered black covers for them which i think will help since the white is so distracting.

New Bed Rack-89.jpg by Monte Nickles Photos, on Flickr

And truck porn!!

New Bed Rack-78.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-79.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-80.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-81.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-82.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-83.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-85.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-86.jpg by Monte Nickles Photos, on Flickr

And a cool sunset to boot

New Bed Rack-77.jpg by Monte Nickles Photos, on Flickr

And a bad video of the setup. You can see its not perfect. But works enough for me for now.

https://youtu.be/zEiRW5DpZ_A

Next up: Limit straps and CO2 bottle on swingout.

I also bought an ARB locker today. And need to decide on rear shocks soon with the t100 axle.

 

Do they do anything like that in the QC stage of manufacturing?

 

Say what???

 

Woot a locker!!

 

yea stoked!

Just a rear for now..but hey ill take it.

 

OMG. Patent that shit. You gonna be rich.

 

haha yea right.

PITA to build anyways.

 

It'll get easier after the first one and you'll always find ways to improve both the design and building process.

 

I put a lot of thought into building a similar set up, great work man.

 

Quality Control. Would they 'fix' rejects to pass inspection rather than destroying them?