Ian's 2004 Tacoma - Custom Flatbed

Someone on another site recommended posting here about my flatbed project. Fabrication is close to done, but it still needs toolbox doors, finish the fenders, wire up the lights and install the deck. Probably a few other things I forgot or missed.

The main feature (for me) is the 18 gallon transfer tank built into the headache rack. Good for the dirt bikes, generators and anything else that needs gas. Tired of hauling around five gallon cans.

Here are two pictures. The first shows the general look and the second shows the fenders. The fenders were started today and seem to be working out so far.

I'll post progress here, as I try to wrap it up.

 

Looks rad, more pics please.

 

A few more pictures of how it went together.

Tacking together the toolboxes. Cut all the faceted pieces on the CNC plasma table. It would have been a nightmare cutting them out by hand. Pretty easy this way.


Finished up the deck supports and side rails.


Finish welded the headache rack and rear fuel tank panel.


Fuel tank filler tube detail.


Last trial fit to check tire clearance, hitch clearance, exhaust clearance and filler tube access. All worked out as planned.




After closing up the fuel tank and pressure testing. Plenty of little leaks got sealed up along weld seams. All good now.

 

Very nice! Bet that plasma table helps with a lot.
@Taco critter

 

Yes sir. That thing is a game changer.

 

I’d believe it.

 

Almost ready for toolbox doors. I've been working on the door flanges that hold the weather stripping. One more to go. I've been using cheap black spray paint to check the results of welding and any grinding. Makes it easy to see the pin holes and other problems, before getting into the final primer and paint. It's easy to remove, since I keep it pretty light.

The front driver side door will cover the fuel filler, but only the front portion can be sealed up. This works with the stock neck and cap. The front portion is where the fittings for the fuel transfer tank get mounted. Gravity feed for now, but I'll add a pump later.

 

Looking good

 

I got three of the toolbox doors done today. Almost had four, but got reversed on the last one. I'll remake it tomorrow. They're working out pretty well, but not as clean as using a metal brake. That is on the short list, but haven't found a good one yet. Again, the plasma table made this a lot easier, including the cutouts for the latches.

 

Are they going to be weather proof? They look good.

 

I'd say more like weather resistant. I have good seals for the doors, but it's hard to keep them completely sealed up all the time. I'm going to make the catches for the latches adjustable. I'll be able to snug them up if needed.

 

Nice, maybe some drain ports or slots? Perhaps with wire mesh.

 

Yeah, I've been thinking about a way to drain the boxes, if necessary. Maybe drain holes with rubber plugs or something. I spend most of my time on dirt roads, so any hole will let the dirt get in. It's amazing how much dirt can get into something that seems sealed up. It's almost like dry lake talc. We call it moon dust. On the plus side, drain holes would let you spray out the boxes and get the dirt out easily.

 

Working on the last few details before installing the deck and getting ready to paint. Should be wrapping this up soon.

Rear tie-downs for hauling plywood and other long things. Not towing points. Those will be down on the bar for the hitch.


Front corner tie downs.


A little branding on the sides of the headache rack.


Fairings/skirts added to the sides of the headache rack.

 

Very nice

 

Cleaning things up for paint and got started on the deck today.

 

The full deck is on with about half the welding done. Tacked on the bottom of the under-deck storage bin. Still need to make the hinged lid for that. Mostly welding in my near future. Then prep and paint.

 

Looking very good. Forward spot turning into an access point?

 

Yes, just a bit more storage for stuff that might not fit in the long rear toolboxes.

 

How much does it weigh? At glance I'd guess somewhere around.. 600-700 lbs?

Or more to the point, I wonder what the net weight difference (probably gain) is vs. the stock plastic bed & sheet metal body.