OutbackHack's Build, solving problems with metal

Finally decided I've screwed around with my truck enough to justify a build thread....

Current setup:
Custom welded front & rear bumpers, sliders, and pop-up camper.
Bilstein 6112/5160 front/rear shocks, OME HD Dakar rear springs, 255/80r17 skinny MT tires

Previous camping setup ~2015


The Beginning Jan 2010


pic dump:


WABDR 2014


freshly welded aluminum bumper



meanwhile in Canada...


West Virginia


Cross Country moving

 

Electrical

Hacked the OEM inverter to include some interior plugs in addition to the stock one located outside in the bed.


Switches for all the things


new engine bay fuse block:
....

 

Bed Rack
The original design




Added spare tire & fuel can mount:




Front Bumper

 

Rear Bumper Build:

The idea...

the two swing arms will eventually support 2x 20L fuel cans, bike rack, and maybe the hi-lift jack. Haven't modeled them yet, but I think the 2x2" square tubing will be a good foundation.

The slow reality...

 

Looks good man. Make sure you get some finished product pictures on that rear bumper!

 

I like your rear bumper.

I ended up buying a Pelfrybilt, but I am going to build a dual swingout, like you have. Have you figured out how you are going to latch the swingouts to the bumper? I have some ideas for mine, but none I really like.

 

Haven't decided 100%, but most likely going with a bolt design similar to the previous swingout I built. Basically a big 1/2" bolt with a handle welded on. Little bit annoying to open and close cause you have to turn it a few times, but I like the security and simplicity. Clamps the arm tightly closed, kills most of the vibration/wiggle that other latches allow, and cheap. Since this will be a dual swingout, I'll probably make a bracket that overlaps the 2 arms so that a single bolt can secure them both.

(not great) pics of my previous bolt latch

 

Did you build a toolbox onto your rack also?? If so how well has it worked out for you?

 

I didn't build the box, but I did attach it to the rack so that the whole thing came on/off the truck as a single unit. Think it was like $150ish when I bought it, not a high quality box, but it kept things dry and easy to access. Wanted a small side mount box since the short bed is short enough already without eating up more space with a typical truck tool box.

https://www.walmart.com/ip/Tradesman-Fender-Well-Tool-Box/19584730

 

Ah ok. Thanks!

Yeah these beds are pretty short, that is why i have a long bed!

 

#ConvertingFromShortBedToLongBedProblems
#TooManyProjectsNotEnoughTime

 

Removed the rear storage and seats to maximize storage, made a carpeted panel to cover the exposed sheet metal and put some insulation back in.

 

What did you make your hinges with?

 

The hinges for my bumper swing outs? I bought them from http://www.4xinnovations.com/

 

Soon...

 

First version of reinforced bed rails to support the camper and give me a flat surface to bolt to. Extended out a bit to match the camper's 76"x66" footprint and compensate for the fact that the stock bedsides taper toward the rear.

First time welding/plasma cutting such long sheets of only 1/8th steel. Metal wants to warp all over the place. The second one came out better after experimenting with a couple different ways of clamping and pre-stressing the metal to make the distortion work for me.

 

So it begins....

 

Really like where this is going.... very nice work on the DIY bumpers ext...

 

spoolgun practice...

 

Criagslist gantry crane...