Shop Floor Talk  

Go Back   Shop Floor Talk > Welding and Metalworking Forums > Fabrication

SFT Search:   
Reply
 
Thread Tools Display Modes
  #1  
Old 08-17-2015, 10:31 AM
Matt Shade's Avatar
Matt Shade Matt Shade is offline
Made From Scratch
 
Join Date: Jan 2007
Location: Ohio
Posts: 3,310
Default Aluminum Flatbed

Some of you might remember my truck from other threads. Have a 2006 F350 I'm still hanging on to. I had it fixed up with a custom headache rack that had a mount for a hi lift jack and served as a base for a toolbox, also had a shovel rack on the drivers side wheel well, and a wheel well box on the other side.

Pics in this thread
http://www.shopfloortalk.com/forums/...ad.php?t=23023


Well the headache rack needed painted and removing it is quite a job. The bed was also starting to rust around the wheel wells and the tailgate was developing a hole. I hate doing bodywork and dont want to just watch the truck fall apart so I decided a flat bed was in order.

I took quite a few pics so I will post them in order. They aren't the best pics but they will give you an idea of how it went together.

The frame and headache rack are done with 3" 6061 channel, all joints were coped. The deck is 3/16" 3003 treadplate.


Cutting was done with a kobalt 12" sliding miter saw with a carbide blade. I spent 100 bucks on a special blade that was for cutting non ferrous metal and promptly bound it up in a cut and broke a a dozen teeth off. Ended up putting a general purpose blade (90 tooth I think) back on that came with the saw and it did the rest of the cuts without issue. Sheets were cut with a 7-1/4" circular saw, or a saber saw (have to lube the blade on this one). It cuts surprisingly easy, but make sure you wear your PPE, the chips are big, sharp and fly all over the shop.

Welding was done with my Lincoln PM216 with the 100SG spoolgun that was included with the welder as a promotion when I bought it. This gun is hobby level at best. It has no spool brake and consequently will not feed stiffer wires like 5356. It runs 4043 pretty good, except it can't handle the amps needed for the stock I was working with. It will weld ok for about 12 inches and then the tip gets hot and it quits feeding. I had to lube the inside of the tips with nozzle gel to get any life out of them at all and I still went through 25 contact tips. To be fair its only rated for 130 amps. Eventually I will probably invest in the their commercial/industrial sized spool gun but they appear to run about $800.

I didn't have the option of building a bed and then sitting it on the truck, so the first job was to strip the truck to the frame, and then the bed was built in place. I should add this is my daily driver so the 1st day was a long one. I started taking the bed off at 7am on a sunday morning and I worked until 9 that night framing as much as I could and getting temporary tail lights mounted. They are held on with zip ties and plugged into the trailer plug.
Attached Thumbnails
Click image for larger version

Name:	flatbed002-DSCF0280.jpg
Views:	389
Size:	102.1 KB
ID:	125832   Click image for larger version

Name:	flatbed001-DSCF0279.jpg
Views:	380
Size:	103.5 KB
ID:	125833   Click image for larger version

Name:	flatbed003-DSCF0281.jpg
Views:	379
Size:	102.3 KB
ID:	125834   Click image for larger version

Name:	flatbed005-DSCF0286.jpg
Views:	384
Size:	107.2 KB
ID:	125835   Click image for larger version

Name:	flatbed006-DSCF0287.jpg
Views:	380
Size:	102.4 KB
ID:	125836  

__________________
Handcrafted Leather
Reply With Quote
  #2  
Old 08-17-2015, 10:38 AM
Matt Shade's Avatar
Matt Shade Matt Shade is offline
Made From Scratch
 
Join Date: Jan 2007
Location: Ohio
Posts: 3,310
Default

I wasn't sure what I would do losing my shovel rack, hi lift jack mount, and wheel well box, so I decided I needed to come up with some extra space. I ended up framing the tail end of the bed in and making a box out of it. It isn't water tight, but it keeps most of the weather out and has room for a couple shovels, ratchet straps and stuff like that.
Attached Thumbnails
Click image for larger version

Name:	flatbed007-DSCF0288.jpg
Views:	349
Size:	104.4 KB
ID:	125837   Click image for larger version

Name:	flatbed008-DSCF0289.jpg
Views:	348
Size:	102.0 KB
ID:	125843   Click image for larger version

Name:	flatbed010-DSCF0291.jpg
Views:	355
Size:	99.8 KB
ID:	125845   Click image for larger version

Name:	flatbed012-DSCF0293.jpg
Views:	348
Size:	104.0 KB
ID:	125847   Click image for larger version

Name:	flatbed013-DSCF0294.jpg
Views:	347
Size:	98.4 KB
ID:	125848  

__________________
Handcrafted Leather

Last edited by Matt Shade; 08-17-2015 at 10:45 AM.
Reply With Quote
  #3  
Old 08-17-2015, 10:51 AM
Matt Shade's Avatar
Matt Shade Matt Shade is offline
Made From Scratch
 
Join Date: Jan 2007
Location: Ohio
Posts: 3,310
Default

more pics
Attached Thumbnails
Click image for larger version

Name:	flatbed014-DSCF0295.jpg
Views:	331
Size:	99.8 KB
ID:	125854   Click image for larger version

Name:	flatbed015-DSCF0296.jpg
Views:	363
Size:	99.1 KB
ID:	125855   Click image for larger version

Name:	flatbed016-DSCF0297.jpg
Views:	344
Size:	99.4 KB
ID:	125856   Click image for larger version

Name:	flatbed017-DSCF0298.jpg
Views:	325
Size:	100.7 KB
ID:	125857   Click image for larger version

Name:	flatbed018-DSCF0299.jpg
Views:	337
Size:	102.1 KB
ID:	125858  

__________________
Handcrafted Leather
Reply With Quote
  #4  
Old 08-17-2015, 10:58 AM
Matt Shade's Avatar
Matt Shade Matt Shade is offline
Made From Scratch
 
Join Date: Jan 2007
Location: Ohio
Posts: 3,310
Default

In order to keep the treadplate flat, I stitch welded it into place starting at one side and working my way across. I used as many clamps as as I could get on it, and then set my 110lb anvil in the middle where it couldn't be clamped. It came out pretty well, the truck is a diesel and at idle the bed doesn't vibrate or make any annoying sounds.
Attached Thumbnails
Click image for larger version

Name:	flatbed019-DSCF0300.jpg
Views:	317
Size:	99.8 KB
ID:	125859   Click image for larger version

Name:	flatbed020-DSCF0301.jpg
Views:	324
Size:	101.1 KB
ID:	125860   Click image for larger version

Name:	flatbed021-DSCF0302.jpg
Views:	315
Size:	100.6 KB
ID:	125861   Click image for larger version

Name:	flatbed023-DSCF0304.jpg
Views:	321
Size:	98.1 KB
ID:	125862   Click image for larger version

Name:	flatbed024-DSCF0305.jpg
Views:	316
Size:	94.9 KB
ID:	125863  

__________________
Handcrafted Leather
Reply With Quote
  #5  
Old 08-17-2015, 11:05 AM
Matt Shade's Avatar
Matt Shade Matt Shade is offline
Made From Scratch
 
Join Date: Jan 2007
Location: Ohio
Posts: 3,310
Default

I already had a B&W turn a ball hitch on the truck for hauling goosenecks so rather than fix what isn't broke I just put a hatch in the floor to cover the hitch. I have to crank the trailer up a little higher when I hitch or unhitch but it works out just fine. It took some figuring to make a hinge that would let the hatch overlap the framing on all 4 edges, but I think it came out ok. I will try to get some pics of what I did for that and post them later.
Attached Thumbnails
Click image for larger version

Name:	flatbed025-DSCF0306.jpg
Views:	312
Size:	98.8 KB
ID:	125864   Click image for larger version

Name:	flatbed026-DSCF0307.jpg
Views:	319
Size:	98.2 KB
ID:	125865   Click image for larger version

Name:	flatbed027-DSCF0308.jpg
Views:	327
Size:	97.7 KB
ID:	125866   Click image for larger version

Name:	flatbed028-DSCF0309.jpg
Views:	321
Size:	99.6 KB
ID:	125867   Click image for larger version

Name:	flatbed029-DSCF0310.jpg
Views:	319
Size:	97.4 KB
ID:	125868  

__________________
Handcrafted Leather
Reply With Quote
  #6  
Old 08-17-2015, 11:13 AM
Matt Shade's Avatar
Matt Shade Matt Shade is offline
Made From Scratch
 
Join Date: Jan 2007
Location: Ohio
Posts: 3,310
Default

Here's more detail shots of the rear tool box. Also a pic of what I did for the fuel filler neck. That will have to be adjusted, if I go to a station where the ground slopes the wrong way I have trouble getting the fuel to run in, not enough angle to it.
Attached Thumbnails
Click image for larger version

Name:	flatbed029-DSCF0310.jpg
Views:	303
Size:	97.4 KB
ID:	125869   Click image for larger version

Name:	flatbed030-DSCF0311.jpg
Views:	302
Size:	101.6 KB
ID:	125870   Click image for larger version

Name:	flatbed031-DSCF0312.jpg
Views:	296
Size:	99.0 KB
ID:	125871   Click image for larger version

Name:	flatbed032-DSCF0313.jpg
Views:	292
Size:	101.2 KB
ID:	125872   Click image for larger version

Name:	flatbed034-DSCF0315.jpg
Views:	293
Size:	105.4 KB
ID:	125873  

__________________
Handcrafted Leather
Reply With Quote
  #7  
Old 08-17-2015, 11:19 AM
Matt Shade's Avatar
Matt Shade Matt Shade is offline
Made From Scratch
 
Join Date: Jan 2007
Location: Ohio
Posts: 3,310
Default

That's all the pics I have for now, although the truck is pretty much done.

I made side boards out of the same 3 inch channel, using 1.5" square tubing for the stakes. 1.5" square tubing is a perfect fit to slide into pockets made with 3 inch channel. The rub rails are 1/4" x 2" flat bar and so far seem like they should be stout enough. I need to get some pics of that stuff and the finished lights.

Main thing left to figure out is putting a resistor in the factory tail light circuit. I patched the new lights into the trailer wiring, and unplugged the old harness at the frame. It recognizes it as a dead bulb now and my turn signals do the rapid flash instead of the normal.
Attached Thumbnails
Click image for larger version

Name:	flatbed035-DSCF0316.jpg
Views:	279
Size:	100.6 KB
ID:	125877   Click image for larger version

Name:	flatbed036-DSCF0317.jpg
Views:	274
Size:	101.8 KB
ID:	125879   Click image for larger version

Name:	flatbed037-DSCF0318.jpg
Views:	301
Size:	98.9 KB
ID:	125881  
__________________
Handcrafted Leather
Reply With Quote
  #8  
Old 08-17-2015, 11:52 AM
5500bill 5500bill is offline
Member
 
Join Date: Feb 2012
Location: MI
Posts: 65
Default

Grote makes a flasher for that. Should be available at parts store. The technical term is hyper flashing Google it and you should be able to com up with a part number
Reply With Quote
  #9  
Old 08-17-2015, 11:59 AM
weldor2005's Avatar
weldor2005 weldor2005 is offline
Perpetuus Discipulus de Vita
 
Join Date: Feb 2007
Location: Marinette, WI - Menominee, MI
Posts: 2,903
Default

It is looking absolutely amazing! I only have one concern that you may want to address, but may just discard as well. I couldn't clearly see your attachment method for the aluminum bed to the steel frame of the truck, and am concerned about the effects of a galvanic cell that is likely to happen. I would suggest figuring out a way to isolate the too from having a current path. This is something to think about with grounding for your lights as well, keep the hot lead isolated from the the bed and then ground lead back to the steel frame. Or possibly have a separate ground from the aluminum bed back to the battery ground. Either way keep the aluminum and steel isolated.



Other than that, the build is looking really nice.
__________________
David

Finch Fabrication
My YouTube Channel

"Of all of our inventions for mass communication, pictures still speak the most universally understood language." - Walt Disney

"Formal education will make you a living;
Self education will make you a fortune." - Jim Rohn
Reply With Quote
  #10  
Old 08-17-2015, 12:13 PM
Matt Shade's Avatar
Matt Shade Matt Shade is offline
Made From Scratch
 
Join Date: Jan 2007
Location: Ohio
Posts: 3,310
Default

Thanks guys

I will look into the flasher, but I think I just need to splice a resistor into the old harness end so that it thinks there is a bulb there.


Good point on the corrosion, I think I have that covered. I used plated grade 8 bolts to bolt the sleepers to the truck frame and there is a layer of rubber treadmill belt between the aluminum and the steel at all points of contact. Lights are tied into the 7 wire harness for the trailer lights, so they have a dedicated ground wire, rather than having to ground through their base, or through a screw to the frame. All wiring is wrapped in split loom as well.
__________________
Handcrafted Leather
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Web Search:

All times are GMT -5. The time now is 11:22 PM.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2022, vBulletin Solutions Inc.