Author Topic: Toyospearo's FLATBED build....(updated jerry can build) (Read 20490 times)

Toyospearo · « **on:** Sep 17, 2009, 09:27:35 AM »

My original idea was to have a shop build a flatbed that I designed. I had a rough idea of what I was after. I wanted the flat bed to accentuate the look of the 94 ext. cab body. Rather than the bed just sitting there like a flatbed, I wanted it to look as if it were designed with the aesthetics in mind. In other words I wanted the flatbed to compliment the 94 body curve to curve. After pouring over the internet for ideas, beating the brush for shadetree fabricators and scouting around fabrication shops I had two conclusions, one, I couldn't afford the labor and two, I couldn't seem to settle on a production/custom flatbed. My only alternative was take a welding class/workshop and learn how to do it myself. :wrench: Luckily I found a great workshop here locally with a brilliant instructor. The workshop was through Unauthorized Art here in Arcata Ca. http://www.unauthorizedart.com/ and the instructor is John Robertson. A few things about John before I move on to the build. In addition to being a brilliant metal worker John is an artist. Here is his website http://www.jonrobertsondesign.com/. :welder:
A GREAT deal of the fabrication design John came up with. Every aspect of this flatbed build John was right there making sure things were coming together correctly. :hillbill:
This flatbed build took one month to complete. Roughly $1000.00 in materials from start to paint as well as an estimated 20 days at 8hrs a day = 160hrs :prop:
On to the build....
This is where it started....

The arsenal...

OH MY MY..

3 Phase PLASMA!!!! :banger:

this was my first project for the flatbed. My Home Depot lock box needed new legs.

A trip to the toy store...

laying out the structure...

mocked up..

Tracing and cutting the headache rack...

Fabbed up the one side, tacked it and mirrored it with the other...

Inside as well as out.. thats how I roll! or just in case I roll :hillbill:

moved the frame in and checked everything out..

headache rack in place, tacked up...

I was sweating that weld... Thats the visible one

Grinding on the headache rack to make it purdy...

While we were finishing up the 45 degree seams on the frame John made this comment "why not make an air tank out of your flatbed frame

"
So we did...
drilled and tapped hole...

TIG weld nut and fitting...

And there is its home...

Testing for leaks. Yes there were quite a few. NO PROBLEM, get out the TIG!!

Finally got the leaks under control. This was the shop PSI after a few take on and take offs. It held at 80 PSI for 4 days. Not a drop of air gone :great:

I have a little 12v air compressor rated at 250 PSI. I wired in a cig lighter in the passengers side compartment where the old jack went in addition to the hose and gauge. It works like a charm. An air tight flatbed holding roughly 8 gallons of air :guitar:
Time for the deck..

I wanted to recess the lock box down in the empty space above the gas tank. It was roughly 4". This also allowed me to secure the box from being stolen...

I made a box for the lock box to sit down in...

I had to stitch weld it to keep the heat transfer correct.

Time for the gas cap..
Cut the hole for placement and did templates for positioning..

Template and the position of the gas cap a little forward to make the hose fitting correct...

Plasmaed the gas hole...

It was easier to weld off the bed..

welded in little nuts to catch the screws from the cap...

Gas line ready PITA...

I thought this was interesting. I made a little video of the MIG dialed at 3 with a 35 line speed...

Trailer hitch and diamond place skirting...
I copied the license plate light template

license plate box. It is part of the structure for the hitch..

I had to use deep welds for this...

Box and rear end..

another little vid...

I knew at some point I was going to have to chop chop...

skirting getting welded on and shined up....

My best weld!! Yes, of course it is underneat

John suggested I make the diamond plate deck removable in order to have it rhino lined. I welded on bolts and angle iron on the frame to attach a lock nut and washer...

This was similar to what John had done on his rig. This set up is for the highlift jack to slide on and off as well as the winches..
I stitch welded the inside bar, plasmaed the holes and plug welded them on the frame and then sanded it all smooth...

Toyospearo · « **Reply #1 on:** Sep 17, 2009, 09:27:57 AM »

Time for PAINT!!!
I used an acid based primer and the paint is an industrial enamel used on most flatbeds...

Primer..

Paint tack coat...

PAINTED!!!

everyone needs a 1 ton hoist!!

LED wiring..

LED load resistors...

Air hose run under the passenger side firewall...

I had some issues with the muffler. I had to cut a chunk out and re weld it...

All wired in...

Deck going on...

FINISHED!!!!!

Here's what keeps it safe at night..

chim · « **Reply #2 on:** Sep 17, 2009, 09:43:35 AM »

Not really my style,... but you are an awesome fabricator and you did a super clean job!!!!!!!!

79coyotefrg · « **Reply #3 on:** Sep 17, 2009, 10:03:07 AM »

is the tire going to hit the jack and load strap winch when you flex or carry a load

94MtnYote · « **Reply #4 on:** Sep 17, 2009, 10:13:22 AM »

thats a sick flatbed, nice design! it is similar to Johns, it's cool how the exhaust comes out one of the pillars on his.
Unauthorized Art is a great place, they have a bunch of sweet fab stuff.

84xcab · « **Reply #5 on:** Sep 17, 2009, 11:30:23 AM »

Absolutely fantastic. you sir are one talented fabricator

79-83earlyota · « **Reply #6 on:** Sep 17, 2009, 12:31:57 PM »

Excellent attention to detail!!! I'm a professional welder myself, so I can appreciate the amount of work you put into it! Great job....you truly have a lot of talent, and should be really proud of an end product like that!

...By the way, nice pics and documentation as well.

One more thing......just out of pure curiousity....do you know how much it weighed at completion? I'm wondering how it compared in weight to the original bed? Not that it really matters, because it looks like you have a good rear suspension set up, but like I said, just curious.

axled89 · « **Reply #7 on:** Sep 17, 2009, 01:55:09 PM »

very nice.

b0x · « **Reply #8 on:** Sep 17, 2009, 02:00:44 PM »

Wow! Hard work paid off again. All you need is a place to hand the grill from, and a bottle opener. And your set for camping.

axled89 · « **Reply #9 on:** Sep 17, 2009, 02:18:02 PM »

you fogot the spot for the keg.

haha ha.

luvyota · « **Reply #10 on:** Sep 17, 2009, 08:38:43 PM »

that looks realy good i like it good job man $Beer Chug\'n$

Toyospearo · « **Reply #11 on:** Sep 17, 2009, 08:51:23 PM »

Quote from: 79-83earlyota on Sep 17, 2009, 12:31:57 PM

Excellent attention to detail!!! I'm a professional welder myself, so I can appreciate the amount of work you put into it! Great job....you truly have a lot of talent, and should be really proud of an end product like that!

...By the way, nice pics and documentation as well.

One more thing......just out of pure curiousity....do you know how much it weighed at completion? I'm wondering how it compared in weight to the original bed? Not that it really matters, because it looks like you have a good rear suspension set up, but like I said, just curious.

Thanks for the compliment!!!
It weighed somewhere in the 350 to 400lb range. A bit more heavy than the bed. However, the weigh is distributed differently. There is more weight toward the center of the truck rather than the entire rear end. I makes for a more smooth ride compared to the original bed.

Halladay · « **Reply #12 on:** Sep 17, 2009, 09:59:27 PM »

AWSOME Work my freind. I really want to build a flatbed for my truck just havnt found i design i really like untill i found this... theres a couple things i would do differnt but thats besides the point. i think you did a great job on this and you should be proud of this one! congrats man.

Toyospearo · « **Reply #13 on:** Sep 18, 2009, 07:05:00 AM »

Quote from: 79coyotefrg on Sep 17, 2009, 10:03:07 AM

is the tire going to hit the jack and load strap winch when you flex or carry a load

Probably

Ryan Zwald · « **Reply #14 on:** Sep 18, 2009, 10:09:24 PM »

I really like it. I wish I knew how to weld.

Did you put drain holes in the recessed area for your tool box?

Toyospearo · « **Reply #15 on:** Sep 18, 2009, 10:22:28 PM »

Quote from: Cheesemaker on Sep 18, 2009, 10:09:24 PM

I really like it. I wish I knew how to weld.

Did you put drain holes in the recessed area for your tool box?

THanks!!
Yes I did put drain holes in the boxed recessed portion of the bed. That was actually the first thing I did when building that box. I live in the pacific northwest where it never stops raining.

79coyotefrg · « **Reply #16 on:** Sep 19, 2009, 01:24:20 PM »

the only thing i would have wanted is maybe a hidden box in the rear above where the stock spare was at, like that Honda Pickup

you can always put the jack up the side of one of the front supports and change that strap winch for a hand winch

YotaChris · « **Reply #17 on:** Sep 19, 2009, 03:05:35 PM »

WOW, Truely an amazing job!!!

Did you happen to put a drain in the air tank potion of the frame??

Toyospearo · « **Reply #18 on:** Sep 19, 2009, 06:28:39 PM »

Quote from: YotaChris on Sep 19, 2009, 03:05:35 PM

WOW, Truely an amazing job!!! Did you happen to put a drain in the air tank potion of the frame??

THANKS!!
I did not put a drain in the air tank.

Ryan Zwald · « **Reply #19 on:** Sep 19, 2009, 07:57:25 PM »

UHMMM!!! I'm more Pacific Northwest than you!!! You are more Central Pacific Coast.

Toyospearo · « **Reply #20 on:** Sep 19, 2009, 08:00:07 PM »

True!!
The rain is worse father north or better depending on your perspective

kneedownnate · « **Reply #21 on:** Sep 19, 2009, 09:39:25 PM »

Hurry up and push this to the 2nd page, then post just a couple pics of the final product please. This thread is super picture heavy and doesn't load for those of us on slow-ass dialup

I wanna see it finished!

Toyospearo · « **Reply #22 on:** Sep 20, 2009, 05:25:24 AM »

Ok!
I am not sure how many more posts until page two but I will post up some more finished pics.

Toyospearo · « **Reply #23 on:** Sep 20, 2009, 05:27:30 AM »

Toyospearo · « **Reply #24 on:** Sep 20, 2009, 05:29:20 AM »

one more..

badshark · « **Reply #25 on:** Sep 20, 2009, 05:38:29 AM »

yeah drain for air tank is a major thing do to condesation? or however that water gets in air compresors rofl but all in ll beautiful job

badshark · « **Reply #26 on:** Sep 20, 2009, 05:39:01 AM »

and ..... BUMP

PA_taco_13 · « **Reply #27 on:** Sep 20, 2009, 05:42:30 AM »

sick! bump for natedog!!!

PA_taco_13 · « **Reply #28 on:** Sep 20, 2009, 05:43:48 AM »

page two calling page two

Toyospearo · « **Reply #29 on:** Sep 20, 2009, 05:47:45 AM »

I didn't think about and air drain.
I am headed out for deer season in the morning and I am going to test my rig out. When I get it back in the shop I need to do a few minor things. One being a drain for the air tank. I also need to mod up a Jerry gas can set up.

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