Flatbed materials (steel vs. aluminum)

[ReluctantTraveler]

I'm working on a DIY flatbed truck camper built on an F-550/5500 platform.

I had originally been looking into aluminum flatbeds for rust resistance, but I'm concerned about steel carriage bolts causing corrosion issues. Similarly, I'd love to have the bed customized with a mounting system similar to what @IdaSHO did with his, and I suspect aluminum brackets will lack the strength to properly secure a camper to the bed.

Any issues with steel? I'm mostly worried about rust. On a F-550/5500, payload is not a huge concern of mine.

 

[ExpoMike]

Biggest concern with steel is weight and rust. If weight is not a concern, it's easier to work with/modify. Aluminum is not hard, just a little trickier. As for rust, epoxy primer and then topcoat with a good paint. You have to get good coverage as thin spots will rust over time. Steel will likely require occasional touch up any place paint has worn off. The epoxy primer will help to keep that a minimum.

 

[ReluctantTraveler]

Biggest concern with steel is weight and rust. If weight is not a concern, it's easier to work with/modify. Aluminum is not hard, just a little trickier. As for rust, epoxy primer and then topcoat with a good paint. You have to get good coverage as thin spots will rust over time. Steel will likely require occasional touch up any place paint has worn off. The epoxy primer will help to keep that a minimum.

Is my assumption that aluminum would not be as strong if mounting with custom brackets correct? The rust-free nature of it is really appealing!

 

[ExpoMike]

Bad assumption. It correctly done, aluminum will be as strong. Remember, they build airplanes out of aluminum. Now whether you have the skill and knowledge to design and build something, that is completely unrelated to the material used.

 

[ReluctantTraveler]

Bad assumption. It correctly done, aluminum will be as strong. Remember, they build airplanes out of aluminum. Now whether you have the skill and knowledge to design and build something, that is completely unrelated to the material used.

I certainly don’t! Nor do I with steel.

i planned to have the flatbed manufacturer build me something custom. Happy to pay for this!

 

[ReluctantTraveler]

Fwiw,
Regardless of strength, corrosion resistance, etc.
Aluminum will be substantially more expensive...

I have no basis for how much flatbeds typically cost.

For say a 9’ bed, what kind of price difference are we talking about?

 

[NatersXJ6]

there is so many unknowns.
But just look at commodity prices of steel vs. aluminum.
Adding specialised skill and equipment to custom fabricate.
You can easily double the price.
Another source for cost approximation.
Look at pricetag of a utility trailer or any other product commonly made of steel or aluminum.
In the case of utility trailers, realise those are often fabricated on jigs from a parts cutlist to more or less cookie cutter design.
Throw in ”custom built”, you can expect price to soar no matter what its made of.

This couldn’t be more true.

Just guessing from what we commonly see for west coast equipment fabrication to our designs in the factory where I work, I would not be surprised if 50% of fabricators simply say no, and the next 50% are anywhere from 3-5x the cost of steel for a finished product that is not mass produced. A happy medium could be galvanizing, at maybe 2x the cost of a bare steel product, but you have to think about heat tolerance in the design as well.

If you are paying someone to design for you, two sayings generally apply 1) The sky is the limit. 2) You usually get what you pay for.

Good luck!

 

[kmacafee]

I've had an aluminum flatbed for 5 years living in a state that loves to salt its roads. No issues so far.

Aluminum will be more expensive than steel but IMHO, well worth the cost and weight savings. Alumline built mine but there are many other options.

 

[ExpoMike]

I have no basis for how much flatbeds typically cost.

For say a 9’ bed, what kind of price difference are we talking about?

If you look at standard, non customized flatbeds in that size, You're looking around a 8K-10K starting price. Some of the more "overland" flatbeds are running in the 15K-25K range. Custom one off, likely north of that. As for steel versus aluminum price difference, that depends on the manufacturer. Typically Aluminum is likely a 20-30% premium.

 

[1000arms]

... I had originally been looking into aluminum flatbeds for rust resistance, but I'm concerned about steel carriage bolts causing corrosion issues. Similarly, I'd love to have the bed customized with a mounting system similar to what @IdaSHO did with his, and I suspect aluminum brackets will lack the strength to properly secure a camper to the bed. ...

Have you asked Duramag Truck Body about any of this?

I know you are aware of Duramag, but I'll add a couple links for anyone unfamiliar with them:

Aluminum Flatbed Truck Bodies and Beds - DuraMag Bodies

Flatbed Aluminum Truck Bodies from Duramag

duramagbodies.com

Custom Truck Bodies - Duramag

Custom Truck Bodies from Duramag

duramagbodies.com

 

[ReluctantTraveler]

Have you asked Duramag Truck Body about any of this?

I know you are aware of Duramag, but I'll add a couple links for anyone unfamiliar with them:

Aluminum Flatbed Truck Bodies and Beds - DuraMag Bodies

Flatbed Aluminum Truck Bodies from Duramag

duramagbodies.com

Custom Truck Bodies - Duramag

Custom Truck Bodies from Duramag

duramagbodies.com

I have. They funnel all inquiries to local partners. Mine was very communicative, and then went radio silent on me about a month ago.

 

[ReluctantTraveler]

If you look at standard, non customized flatbeds in that size, You're looking around a 8K-10K starting price. Some of the more "overland" flatbeds are running in the 15K-25K range. Custom one off, likely north of that. As for steel versus aluminum price difference, that depends on the manufacturer. Typically Aluminum is likely a 20-30% premium.

if it’s “only“ 30% more, I’d actually be happy to pay that much for an aluminum flatbed. I live in the northern part of the US, where roads are heavily salted. Not having to worry about rust would be amazing! If it was twice as much, I would probably just go with steel.

 

[Alloy]

if it’s “only“ 30% more, I’d actually be happy to pay that much for an aluminum flatbed. I live in the northern part of the US, where roads are heavily salted. Not having to worry about rust would be amazing! If it was twice as much, I would probably just go with steel.

I work with both alum and steel. Aluminum cuts, welds and fabricates 3X faster than steel. By the time you make steel rust (galvanizing) proof it is close to the cost of alum.
Rule of thumb if you're comparing decks. Alum is 1/2 the strength and 1/3 the weight. Stay away from alum decks that are 1/2 the weight of steel.
If you call Dodge/Ford Fleet dealers they can give you names of outfitters that do alum. Another source is boat/marine fabricators.

 

[ReluctantTraveler]

I work with both alum and steel. Aluminum cuts, welds and fabricates 3X faster than steel. By the time you make steel rust (galvanizing) proof it is close to the cost of alum.
Rule of thumb if you're comparing decks. Alum is 1/2 the strength and 1/3 the weight. Stay away from alum decks that are 1/2 the weight of steel.
If you call Dodge/Ford Fleet dealers they can give you names of outfitters that do alum. Another source is boat/marine fabricators.

this is awesome! Thanks so much!

I know a lot of these vendors focus on weight or up charge for Overland rigs. Your advice sounds like a great way to go.

 

[1000arms]

I have. They funnel all inquiries to local partners. Mine was very communicative, and then went radio silent on me about a month ago.

Perhaps a quick contact with Duramag, letting them know the situation and that it appears you might need a new local partner, would be useful?