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Interesting, I’ve never seen that. I’d still get radius angle though for the strength. Much stronger. Sent from my iPhone using Tapatalk

The angle you attached appears to be architectural angle, not structural. I would recommend getting structural 6061 since it has the radius bend. As for the tig welded reinforcements, I would not weld them. your HAZ near the weld loses a lot for strength. I would just use more rivets if you're...

Looks like I need to rethink my spring mounts. The problem is that the ford factory mounts require ~60ft-lb of torque to seat/compress properly. that amount of torque fully compressed the spring with ease: it requires very little torque to compress the springs. I could get a spring with as much...

Looking to get a couple very specific measurements on an Xventure (any model really) trailer. If you're willing to take measurements, or local to San Diego so I could check it out, please let me know!

I considered a guide plate, but I don't think it's necessary. At the top and bottom of the ford bushings, along with the aluminum subframe are three holes with an inner diameter near exact to the 1/2in bolt. This should prevent most of the movement. Also the box is mounted rigid to the cab, and...

Subframe Mount Parts Mockup Finally received all of the parts to mock up my subframe mounts. Things are looking pretty good. Only thing I plan on changing is the size of the bottom washer/keeper ring. (Aluminum part has since been redesigned)

There is not. There is no way around getting the special tool. Otherwise you could use standard rivets if you found some strong enough for you.

blindrivetsupply is the cheapest I've seen, but haven't done much digging. The tool is very expensive so I would definitely look into renting/borrowing/used one. just normal 6061 angle cut to size. yep WAY higher risk of failure at the weld or more nearby in the HAZ, and countless examples...

Yes I'm aware thats the way the completed ES Bushings come, I was initially planning on just using those before deciding on the ford factory mounts. I'm not using there universal completed bushings, just one of the poly pads they supply.

I was considering this, but I feel like theres already a lot of bushing in there! I'm thinking it won't matter since I have bushings on both sides of the frame already? This is also the way the factory ford mounts work if I just used them as is. Happy to be proved wrong just with already having...

Spring Mounted Subframe Design I roughly measured the frame flex of the chassis at ~6in of vertical displacement, meaning the mount right behind the cab is 6in lower/higher than the rear mount on the opposite side. It's expected that the chassis will flex a lot without any box, as the frame is...

Aluminum Weldless Subframe Construction Technique Consideration Thought I should share a new subframe fastening technique I am considering as opposed to welding the aluminum. The company XVENTURE makes military trailers as well as overland trailers with this technique. Essentially you rivet...

Current plan is to do a TIG welded aluminum frame, but I am also considering steel. I agree and am also nervous working with aluminum: This is currently the biggest decision I face. To preface, I am not a metallurgist or mechanical engineer, but here is my understanding: 1.) When you weld 6061...

Next step will be finalizing the design on the spring mounts, one of the most important parts of the build IMO. I have the design pretty finished and will post about it soon! Once this is ready to go, I'll start constructing the subframe.

Exterior Plans: The basic plan for the exterior is to do a spring mounted aluminum subframe with a welded aluminum exoskeleton. DIY Composite panels will then be adhered to that. The pop top will then mount the aluminum skeleton and raise vertically.

Interior Plans: I plan to go into this more in depth later, but for now a quick overview: There will be a full roof pop top, and 10ft long of interior living space. The bed will go front to back, which is the only option given my height. This means the bed will be almost the width of a...

Cool E350 Composite Camper Specs: Overall Width: 80in (Dana 60, same as full-size) Overall Length (with 10ft habitat): 212in (6in shorter than a jeep gladiator!) Wheelbase: 137in (Same as jeep gladiator) Insanely good approach angle, reasonable breakover, and good departure 16in of front wheel...

Vehicle Considerations: Here is a high level overview of our must-haves: Interior sleeping (stealth option also, ie no pop top raised) A configuration that allows me to stand up completely and comfortably An comfortable indoor space for all weather situations (rain, snow, -30º to 80ºF ish) Room...

Officially starting the build thread for our E350 Cutaway 4x4 w/ DIY Pop-Top Composite Camper Box! First, why a new build? The initial plan (many years ago) was to convert a high roof Transit Van. The cost of that wasn’t an option at the time, so we ended up with an Overland-setup SUV to hold...

I also agree with not overloading a vehicle if you can, and plan to stay well below on my next build, however I think this class of Nissan is a bit of an exception. Here is my experience coming from an Xterra: The Xterra shares the same frame with the Titan (although shortened) which has 2klb+...