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Old 03-21-2017, 08:41 PM   #76
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Building the boxes for the rig



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Old 03-24-2017, 06:48 PM   #77
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plodding along





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Old 03-25-2017, 07:36 AM   #78
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Default Re: TV Build

That is looking awesome.
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Old 03-25-2017, 03:27 PM   #79
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Thanx
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Old 04-02-2017, 06:18 PM   #80
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I knew this would be a lotta work. About got all the major fab work done and ready to move on to the little things, shelves, wire chases, lights, etc... I still need one door/hatch cover to go over the fuel pump box on top. I'd like to make this one out of lighter material, cross bend it so it is crowned upward just a little to shed water. Unfortunately the opening is 1" larger than my home made break bender.

I should probably wait to fit the door hinges but after all the hours it helps the motivation to jump ahead a little bit.

Door openings



test fit a couple doors. Using bullet hinges. The top door will have gas shocks. I'm still deciding if the bottom channel of the top box needs to have a drain put in. The way it leans back it will collect water I don't really care about the water it's just when it freezes it may pull out the weather stripping when the door is opened.



The top box for the fuel pump, hose and fill neck. This was an after thot and it would have saved some welding if I had cut the plate different. Basically I got tired of having to lock both the fill cap and the pump. Plus the drips run down the outside of the tank and spray onto the rear window. I will add a drain line from the box down the outside of the tank. I need to do the leak check first.






Current weight estimated to be about 700#
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Old 04-05-2017, 08:21 PM   #81
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Cutting holes makes me nervous, it signifies commitment

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Old 04-06-2017, 06:08 AM   #82
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Default Re: TV Build

how big is the piece you need or want to cross break?
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Old 04-06-2017, 06:13 AM   #83
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Default Re: TV Build

Always hated cutting holes. once you do you have a lot of work to undo it if you were wrong. or changed your mind.
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Old 04-06-2017, 07:33 AM   #84
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Quote:
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how big is the piece you need or want to cross break?
Hey James, it will be about 39" across
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Old 04-06-2017, 08:24 AM   #85
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if your coming to anchorage anytime or eagle river, you can drop it off and i can take it to work and hit it if you want.
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Old 04-06-2017, 12:12 PM   #86
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Default Re: TV Build

Cut outs for lights?
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Old 04-06-2017, 01:09 PM   #87
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Cut outs for lights?
yes, also cut in a bunch of latch handles
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Old 04-06-2017, 01:10 PM   #88
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if your coming to anchorage anytime or eagle river, you can drop it off and i can take it to work and hit it if you want.
thanx James. I just picked up the materials. Lets see what the next week brings
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Old 04-08-2017, 02:12 PM   #89
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Still plodding along. It's all about the little details now.

Test fit a pair of lights



Made a bunch of shelves and holder for cordless tools, still need to make mounting brackets for things the will be semi permanent.







And I took a shot at making the top hatch. I wanted it cross broke to shed water.



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Old 04-08-2017, 07:16 PM   #90
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Default Re: TV Build

Will you have an inverter on the truck to allow charging your tool batteries?
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Old 04-08-2017, 07:54 PM   #91
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Will you have an inverter on the truck to allow charging your tool batteries?
probably
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Old 04-09-2017, 12:31 PM   #92
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Default Re: TV Build

least a shore power connection so at home it can be plugged in at night to charge everything up. I am a can of chargers. The shore power on my truck runs a 1.5 charger on the truck battery, an outlet in the cab and a power strip in my work box for rechargeable lights and power tools. would like to add in inverter eventually, but I may be getting a new bigger truck we I am waiting to see what happens with that first.
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Old 04-09-2017, 05:07 PM   #93
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It will have power of some kind. I was originally thinking I'd mount a small genset in a box under the bed. I am also now looking at inverters.
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Old 04-13-2017, 08:35 PM   #94
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Finally got to test fit the box and make the mounts. I still have to build a pair to fasten to the side of the frame.







Then it's all about adding the little things ... like gas shocks to hold the upper doors open

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Old 04-13-2017, 08:48 PM   #95
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The rails for the 5th wheel hitch arrived so I can get serious about the flatbed. A chassis cab frame is narrower than a standard pickup frame so some heavy thinking was required to figure out how I want to mount them. They will be permanent Everything except the outer frame is just tacked. Most of it will have to be knocked apart after it has all been fitted so it can be welded out.

There is tube with ears for bolting or welding under the rails. The specs for the 20k hitch rating require the center of the rails to be fastened, normally with bolts, to the frame.






I think I will cut the rails off at the outside edge of the frame. Then the bed to frame mounts can extend up past the rails and be welded to that tube with the cut outs.
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Old 04-13-2017, 08:58 PM   #96
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For those that wonder, the 5er pin is 6" forward of the axle centerline. It will carry the load much better than the normal installs found in typical pickups where the pin is over or just an inch forward of the axle. I may have to hook up the the 5er before welding everything out to be absolutely sure I can jack knife the trailer and not hit the bed or boxes. All the measurements look good but there is nothing better than hooking up to be 100% sure.
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Old 04-13-2017, 10:41 PM   #97
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Nice work!

I just saw your mini-me on FB:

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Old 04-20-2017, 08:44 PM   #98
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I got the deck all framed and the hitch brackets for connecting to the frame. I got some warping in the main stringers that I am working to get out. I made some u-bolt like clamps, left one bolt in the rear mounts, put 1/2" blocks under the hitch and started tightening the u-bolts as far as I dared. The center pulled flat but the outer rails still have about a 1/4" bow. Not sure how I can pull it out and It'll only get worse when plating the deck and sides. I really need something like a 8' x 1/2" piece of angle iron or 1/2" wall square tube.

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Old 04-20-2017, 08:46 PM   #99
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While I think on how to get the outer rails straight I moved on to cutting plate.





The ball hitch looks kinda cheesy but I didn't want to fab a new one from scratch so I cut around it. Maybe when it's all done and painted it'll look better





The license plate box is a bit oversized and will be removable so I can reach the nuts on the rear mounts and the wiring junction box in the rear of the frame.
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Old 04-20-2017, 08:57 PM   #100
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I decided to go with a 24" wide full fender to cover both tires. Weld Air is doing the roll bending. I'd like to roll bed some pipe for a nice edge. Will wait to see how it looks. If someone here has a roll bender I could borrow for a couple days...
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