thebigblue
Adventurer
Me like 
Meet the Trot'n Turtle - Unimog U1300L Build
- Thread starter Hodakaguy
- Start date
Hodakaguy
Adventurer
Time to start on the roof rack project. I looked at a lot of different pictures of existing roof racks on U1300's and considered several designs. In the end I really like the looks of the Atlas4x4 roof rack, simple and clean design. I want to use different lights than what Atlas provides so that leaves fabricating it ourselves so we can use the correct mounts and spacing for our lights.
I looked at building the rack out of both Aluminum or Carbon Steel, aluminum would save about 60 lbs but cost 3-4 times as much. In the end I decided on Carbon for both cost, availability and easy of construction. The mog won't notice this extra 60lbs
Building the outer hoop: I settled on 2" tubing for the outer hoop of the rack as this size seems to fit the cab nicely. I really didn't want to use weld on 90's for the corners so that leaves bending as the preferred option. I don't own or have access to a bender capable of bending tight radius 90's on 2" tubing so I will have to source this job out. It turns out finding someone to bend tight radius (3" radius) 90's on 2" tubing is only slightly less difficult that turning lead into gold, after quite a few calls I finally found a place that would do the bend work for me.
Here's the hoop back from the tubing bender. We were using shims on the floor to level the hoop.
Starting to cut the cross members, they will be rectangle tubing. Notching the ends to saddle properly onto the tubing, a 2" washer works great for marking the line.
The three sender pieces installed, the mounts that attach the roof rack to the cab will be supported from these bars.
Dad tacking the assy up
Starting to install the cross members, there will be two of these running the length of the rack.
More to come.....
Hodakaguy
I looked at building the rack out of both Aluminum or Carbon Steel, aluminum would save about 60 lbs but cost 3-4 times as much. In the end I decided on Carbon for both cost, availability and easy of construction. The mog won't notice this extra 60lbs
Building the outer hoop: I settled on 2" tubing for the outer hoop of the rack as this size seems to fit the cab nicely. I really didn't want to use weld on 90's for the corners so that leaves bending as the preferred option. I don't own or have access to a bender capable of bending tight radius 90's on 2" tubing so I will have to source this job out. It turns out finding someone to bend tight radius (3" radius) 90's on 2" tubing is only slightly less difficult that turning lead into gold, after quite a few calls I finally found a place that would do the bend work for me.
Here's the hoop back from the tubing bender. We were using shims on the floor to level the hoop.
Starting to cut the cross members, they will be rectangle tubing. Notching the ends to saddle properly onto the tubing, a 2" washer works great for marking the line.
The three sender pieces installed, the mounts that attach the roof rack to the cab will be supported from these bars.
Dad tacking the assy up
Starting to install the cross members, there will be two of these running the length of the rack.
More to come.....
Hodakaguy
Iain_U1250
Explorer
Great fabrication skills, I was never able to get my tubing to fit anywhere near as tight at that, so my "gap filling" skills with the welder are now quite good
Hodakaguy
Adventurer
Great fabrication skills, I was never able to get my tubing to fit anywhere near as tight at that, so my "gap filling" skills with the welder are now quite good
Thanks guys. I would love to get more into tubing bending and forming, lots of cool stuff you can do!
Hodakaguy
Hodakaguy
Adventurer
Up early this morning and finished the drivers side marker guard, well mostly finished I still have a little a little blending to do on the mounting tabs.
Next up I cut and tacked the remaining cross members into the rack.
Dad doing his thing and welding out the cross members.
All welded out.
Rack set in place on the truck. The rack will be placed high enough to allow the vent hatch on the roof to fully open even when something is strapped down on the rack. Here we are getting ready to mark out the cuts on the passenger side corner to allow clearance for the cyclone filter.
Cyclone filter removed and rack centered on the cab.
Laying out the cut lines for the cyclone filter clearance.
More to come soon...
Hodakaguy
Next up I cut and tacked the remaining cross members into the rack.
Dad doing his thing and welding out the cross members.
All welded out.
Rack set in place on the truck. The rack will be placed high enough to allow the vent hatch on the roof to fully open even when something is strapped down on the rack. Here we are getting ready to mark out the cuts on the passenger side corner to allow clearance for the cyclone filter.
Cyclone filter removed and rack centered on the cab.
Laying out the cut lines for the cyclone filter clearance.
More to come soon...
Hodakaguy
patoz
Expedition Leader
It looks to me like you only need a few inches for the filter to clear, so could you not just shorten the filter riser tube enough to gain that clearance? Or would it hit the vehicle body if you did?
I know it's going to look good no matter how you do it, but I was just wondering.
I know it's going to look good no matter how you do it, but I was just wondering.
ambulancemonkee
Observer
This is my new favorite build thread.
patoz
Expedition Leader
Hodakaguy, I thought you might like this. I see a lot of similarities in this build and the direction you're going.
I love this paint job and if you build a set of folding stairs like this vehicle has, take lots of pictures because I want to see how you do it. I need to build a set also, but shorter for an ambulance.
I love this paint job and if you build a set of folding stairs like this vehicle has, take lots of pictures because I want to see how you do it. I need to build a set also, but shorter for an ambulance.
Hodakaguy
Adventurer
The fire trucks are hard to beat for cond as they are usually well kept and maintained. Some of them can have 7th gear synchro problems as they usually are racing to an emergency and they slam them back into 7th trying to maintain speed on hills. Doesn't affect all trucks, the units with water tanks can be affected worse because of the weight. Something to look at and ask when looking at fire rigs.
Hodakaguy
Hodakaguy
Adventurer
That thing is a beast! The slide out step is pretty cool, Atlas4x4 has a similar unit available: http://atlas4x4.de/portfolio-item/aufbautreppe/
Hodakaguy
patoz
Expedition Leader
That would do it...if there was a shorter model. Can we buy from them being here in the USA? I didn't see any prices or any way to order products.