Build an Alloy Base Tray, Dual Cab

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Build an Alloy Base Tray, Dual Cab

1

Step 1 of 25

It looks like this when it is all tacked up

2

Step 2 of 25

Lay the chassis rails onto the table

3

Step 3 of 25

Flip it over and insert the three times rivets on the underside to hold the rails together

4

Step 4 of 25

<p>There should be three rivets per chassis rail</p>

There should be three rivets per chassis rail

5

Step 5 of 25

Flip the rails back over so they are in the correct orientation

6

Step 6 of 25

Lay on all the crossmember the little Laser arrow should point towards the front of the Tray

7

Step 7 of 25

<p>The Laser cut Arrow should point towards the front of the Tray</p>

The Laser cut Arrow should point towards the front of the Tray

8

Step 8 of 25

Rivet down all the crossmembers with the rivets which are long enough for 8mm

9

Step 9 of 25

Fit the back Ladder rack mounts. The Laser cut Arrow should point towards the front of the Tray.

10

Step 10 of 25

Tack weld it into place

11

Step 11 of 25

<p>Get the gunnel rail extrusions</p>
<ul>
<li>Qty 2 @ 1725mm for sides</li>
<li>Qty 1 @ 1730mm for back <strong><em>You will need to use the cut off saw to trim 10 mm from the ones which we have been supplied with</em></strong></li>
</ul>

Get the gunnel rail extrusions

Qty 2 @ 1725mm for sides
Qty 1 @ 1730mm for back You will need to use the cut off saw to trim 10 mm from the ones which we have been supplied with

12

Step 12 of 25

<p>Get the rope rail extrusions</p>
<ul>
<li>Qty 2 @ 1642mm for sides</li>
<li>Qty 1 @ 1830mm for back <strong><em>You will need to use the cut off saw to trim 10 mm from the ones which we have been supplied with</em></strong></li>
</ul>

Get the rope rail extrusions

Qty 2 @ 1642mm for sides
Qty 1 @ 1830mm for back You will need to use the cut off saw to trim 10 mm from the ones which we have been supplied with

13

Step 13 of 25

<p>Notice that the when view from the back, the rope rail support pieces all lean to the centre</p>

Notice that the when view from the back, the rope rail support pieces all lean to the centre

14

Step 14 of 25

<p>Mark the position of the support pieces on The back of the Tray</p>
<ul>
<li>At side</li>
<li>390mm</li>
</ul>

Mark the position of the support pieces on The back of the Tray

At side
390mm

15

Step 15 of 25

Tack weld them in place

16

Step 16 of 25

<p>Mark out the position of the support pieces on the sides of the tray. <strong><em>Notice that all of the rope rail support pieces lean forward towards the headboard.</em></strong></p>
<ul>
<li>At back</li>
<li>380mm</li>
<li>760mm</li>
<li>1180mm</li>
</ul>

Mark out the position of the support pieces on the sides of the tray. Notice that all of the rope rail support pieces lean forward towards the headboard.

At back
380mm
760mm
1180mm

17

Step 17 of 25

<p>Mark out their positions</p>

Mark out their positions

18

Step 18 of 25

Tack weld them in place

19

Step 19 of 25

<p>Fit the gunnel rails and tack weld them in place</p>

Fit the gunnel rails and tack weld them in place

20

Step 20 of 25

Position the front Ladder rack pieces

21

Step 21 of 25

Tack weld them into place

22

Step 22 of 25

Cut the Uni strut rail profile

Dual Cab: Cut length is 1600 mm, qty 4

23

Step 23 of 25

Fit the Uni strut rail

24

Step 24 of 25

Fit the license plate Light bracket and rivet it in place

25

Step 25 of 25

It should look like this