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Lots of measuring and making stuff ( in the computer ) So this is basically that I am working with right now. In the first picture you can see how setting a 'halo' on the top of the B-pillar will look. I tried to guess at the 'stock' position of the door opening in relationship to the...

I purchased them from Sharpe Products. http://www.sharpeproducts.com/store/square-tube-elbows

Just a few sneak peaks because all I did was stare at things for like an hour and measure stuff.... This is one of the square tube mandrel bends I will be using to form the rear of the tub. I will be using 4 total, 2 per side. One per side will be similar to this location but not exactly...

I don't know about all that, but thank you for watching.

A little how-to tech tip.... Sometimes, when working with more complex shapes, I find it handy to use an 'additive' process for making templates rather than a subtraction method. In this case. I used making tape to make a skin over the area where I needed a boxing plate. I trimmed that...

No problem. Thank you for watching.

I finally finished up the passenger side of the rocker protection outrigger body mount project extravaganza!

Thank you. I have been working on the 2nd side, it was just as much work as the 1st side! I am surprised how much time I have in these assemblies. They serve a lot of functions, but dang, sometimes even I am surprised by some of this stuff. It will be nice to be able to move onto a new part...

It's hard to see, but there is a 3/8" drain hole at the low point of each outrigger box near the frame plate. That should allow me to flush them out with a pressure washer. They will gather mud, but I didn't want to try and make a completely closed assembly. The vertical sides extend past the...

Not the same application, but this is what I did on my 80-series framed FJ45-esk truck project... I used 2x3x3/16 wall A500 rectangle tubing as a base. The outrigger is constructed of 10 gauge cold roll sheet and they also contain the body mounts for the tub. For this weight vehicle, and a...

Nothing lined up yet. I have been building a new Toyota-ish LandCruiser FJ45-ish pickup thing lately.

No. I am a slacker. I have been working on my new landcruiser truck thing. I still drive the dodge every day. It keeps running. I can't complain.

One side done.... Now onto the other side.....

I can measure next time I cut a hole, but all the holes so far where pretty dang tight on the dimple die stem. I would say less than .03" slop. I will measure next time, I have lots of holes and dimples to make.

I will try and use them tastefully.... I have made ones for odd jobs in the past, I finally had to break down and buy a 'real' set. The Blair Holcutter's are the other part of the puzzle. I have developed a distaste for most hole saws lately. Part of the problem is that I need a much more...

Some more this evening... I purchased a matching set of Blair Holcutter's to my dimple dies. These things are great! They cut fast, but require pretty high power. The 2" version will bog down my Bosch 3/8" drill. If you don't pay attention they can grab and throw you.....yes they can. You...

I finished up roughing in the drivers side A-pillar body mount outrigger rocker support. It was pretty much identical to the passenger side. There was a few small differences in where the firewall brace structure was. Now it's time to pull each side seperately for final boxing and...

I don't think it is that simple. As the sport has advanced there has been a big push to have more up-travel while trying to keep overall height down. My flat fender is a good example of how that can be done. It is still 'stock' suspension height basically, if not slightly lower than stock, but...

Just duplicating the A-pillar rocker outrigger on the drivers side... This is how I pressed the part that needed to form around the multiple steps on the rear of the mount. There are 3 levels in this. I was able to assemble a simple one off press brake die using scraps I had laying around...

Ah. This truck is just too big for the crazy places I tend to end up, for everything else it works really well. I tend to be a little more bias towards tight technical type wheeling where full size vehicles typically will have the bodies destroyed over time. I still love this thing for...