Broken frame at rear leaf spring/Flatbed build

I rolled the flatbed through the scales today without any wood decking installed and she came in at 4120lbs. Dry weight is around 3390. I'm about 170 and with gas and fluid I've only added roughly 550lbs which really isn't as much as initially thought.

I think since the back bumper is pretty hefty and it hangs off the back so far shortening the flatbed bed 12-14 inches will do a lot. I'm also going to cut some holes if needed and relocate my spare tire.

 

Going to attempt to remove 12 inches from the flatbed, cut out the spare tire hanger, and shorten the rear of the frame by about 6 inches.

 

Awesome work, I can see why the Dakars are having trouble holding that weight though...Dakars aren't meant to hold more than what the stock springs do really. An add a leaf in them only increases their capacity by 70lbs or so, I forget exactly but it's minimal. I went through Dakars then Dakars + AAL and eventually had to upgrade to Alcans because the Dakars couldn't even hold my tent and camping gear weight without sagging on the bump stops.

I think the weight saving measures you're doing will help but you'll still need stronger leaf springs I bet. I would look at the All Pro Expedition springs or better yet, a custom set build by Deaver or Alcan. They'll build them to hold exactly how much weight you want them to and to the lift height you want.

 

Thanks bud. I'm preforming the surgery now. I'm thinking of maybe adding air bags to help with the weight. I'm leaning that way since the springs are brand new and I'd like to keep them.

If they're not going to cut it I'll definitely go with some custom leaf packs and likely sell the Dakars.

 

So far so good.

 

Question,
When you were welding on the safetcap things after painting them, did you have any trouble with bubbling or peeling? I'm working on my frame, trying to decide the best course of action. If POR-15 doesn't peel with heat, it seems like the way to go.
Btw, that's a sweet looking bed, fabbing stuff is so much fun.

 

I didn't. I left about a half inch border around the paint. Looking back I would have just painted the inside and left the outside raw steel and painted afterwards.

 

Por 15 will peel with enough heat.

 

Yeah, I was just thinking most paint would peel even with that distance.
I guess you don't know what the inside looks like.

 

I plan on painting what I can and coating the inside with cos moline.

 

Back end off. Now time to clean up my weld points and start shedding weight.

 

End section removed. Will clean up the cut surfaces, see if more weight can be shed on the backend, and get her welded back together.

 

Shortened the whole bed by 12 inches and removed some more excess weight. I'm really liking the look and the leafs look a lot better. I still need to gsin a couple more inches but I'm getting there.

 

cos moline? sorry, I'm clueless.

Do you have any idea how much por 15 you used altogether?
Your making me want to build a flatbed

 

Cos moline is a rust preventive wax coating commonly used by armed forces around the world. You can find it on Amazon in aerosol cans.

A little Por15 goes a long way. I bought a gallon of base coat and gallon of top coat and have about 1/2 to 3/4 left. Don't forget the degreaser and metal etch. Prep is key.

 

the time will tell if that Por15 is made to last or not!
i read and heard enough bad experiences from using it that dissuaded myself and go another route that maybe has less prep involved
just clean all the peecoating off, afterblast zinc coat clean metal and apply two coats of extreme chassis primer. after a light, fine-grit scuffing add extreme chassis topcoat
but not many on here use this extreme stuff so idk if its any good or not
i suppose we can compare in 5 or so years and i can redo it if mine turns out to be sucky sucky

 

Ok, Thanks for the info.

 

I've read a lot of both positive and negative reviews por15. I think a lot of the issues come from prep or lack thereof. Time will tell though.

 

Beginning the welding of the 2 sections together. So far so good. Getting everything to line up was a serious struggle.

 

My springs are pretty much flat with all my aforementioned weight, and it seems that is a pretty common condition.

Hopefully the weight reduction will be enough!