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Flex test I lifted the truck same as before, same tire, same side, and had to lift the truck 2 more inches before the other side lifted, the truck got a little stiffer, and the suspension took up the flex. We measured between 3/8 - 1/2" of twist in the bed. So we reduced the factory flex by...

The rear bumper is heavy, I'd say 250 lbs. I screwed up and forgot to weigh it individually, and I'm just building the prototype with quick 2D CAD files, I've been building stuff for a very long time with the same equipment and tooling so I know my tolerances and radius's off the top of my head...

It's a little fatter than I like Took a trip to the scales, front axle weighs in at 2130 KG (4695 lbs.), and the rear axle came in at 1360 KG (2998 lbs.) Front axle is 20 KG (44 lbs.) heavier than stock, rear axle is 100 KG (220 lbs.) heavier than stock, total deck/bumper/hitch weight is 390 KG...

Thanks guys, hopefully the rest turns out as good. Remember what they say about the last 10% of a job!

The rubber floor I want a non slip, damage resistant floor, my truck had a 5/8" rubber mat in it for 11 years, it has hauled everything! And no damage to the floor. So I sunk the floor plate 1/2" below the sills, this will leave the rubber matt protruding 1/8" above the sill, this on top of a...

Dual shear plate design. How's that for a colour match, 11 year old silver paint and fresh powder. All wiring and lighting is enclosed in the rear bumper, anything over 76" wide in Canada requires all of the clearance lights I have installed. Generally you can get away without it in a...

Bumper details. Just some bumper details. The tow lugs are designed for a shackle and a hydraulic motorcycle lift at the same time. If there is any capacity left I will try to set it up to carry at least one MC, The lift is being designed to utilize the receiver and be stabilized off of the tow...

Some details: The headache rack is a bolt on, can be made to accommodate individual needs, The "shoes" are wheel chocks and tie down points for bikes, the headache rack and wheel chocks are all 3/16 aluminum. The whole assembly is 2" thick, and the headache rack is only a 1/2" from the back of...

On with the deck! The sills are drilled to catch every crossmember. 4 1/2" stainless bolts grab every crossmember. The sills are held to the factory mounts with 5/8 grade 8 bolts and stover lock nuts, overkill for the application but they fit the stock holes nicely. I hate grossly oversized...

I decided to redo the rear bumper, I upped the shear plates to 1/4", bumped the hitch tube side from 3x3x.250 to 3x4x.250 for a little better look. I increased the height a little to balance out the look and keep things centred. I also increased the size of the license plate box and mounted the...

A good steam cleaning, removed some of the flaky stuff with the wire wheel, and a quick shot of chassis black made it look like new. I was surprised at the condition of the original paint, especially with our corrosive winters. A new set of pro Comp adjustable shocks will help tune the ride in.

Here is the deck, 2x6 C channel perimeter, 3" C channel cross members, all 1/4" 6061 T6. The deck is covered with 3/16 aluminum diamond plate, 5052, all welded with a Miller 350P welder.

I designed a mounting sill to fit the factory mounts, I wanted to keep the floor of the deck as close to the factory box floor as I could, the sills are 3/16 50W steel with windows cut for shock and frame component clearance, all windows are capped. With a 3" crossmember and enough vertical wall...

How much flex does the box have to deal with? With the box and bumper off, I decided to see how much flex the box took out of the chassis. As you can see the box stiffens the chassis a little, I expected to see a little more but I measured 3/4" - 7/8" of flex, so roughly 1/8" - 3/16" of...

After establishing a few basic parameters, I stripped off the box and rear bumper, I want to find out what they weigh and the effect on axle weights, all weights were with a half tank of fuel, and no occupants. Front axle 2150 KG (4740 lb) 40 KG or 88 lb HEAVIER! Rear axle 950 KB (2094 lb)...

A couple angles on the amount of flex transmitted through the box.

How flexible is it? I considered a 3 point mounting system, everybody need that right? Well why don't we find out what we are dealing with. It's not like the old days when the box of the old Chevy would beat the required clearance into the cab in the rough stuff, truck chassis suspension has...

First step Weigh it! What can it haul? Front and rear axle weights stock with box and a Trail Ready rear bumper. 2110 KG front (4650 lb) and 1260 KG rear (2777 lb), total 3370 KG (7427 lb). Heavy truck! That is with a Trail Ready front bumper, 4" Fabtech lift, and 35" Generals on aluminum...

So a few years ago, I built a nice Ford F-650 to comfortably haul 4 people and sleep up to 6 for our families travels, we race cross country and hare scrambles plus do a lot of off road riding. In the past we used your typical RV but after killing 2 motorhomes, 2 travel trailers, and having the...

Changed oil in the little Cummins……made sure nothing was falling off!