The Frankenstein Build: 1996 Tacoma Long Travel/Expo/Trail Rig

[Blackdawg]

LongTravel Install-145.jpg by Monte Nickles Photos, on Flickr
LongTravel Install-146.jpg by Monte Nickles Photos, on Flickr
LongTravel Install-147.jpg by Monte Nickles Photos, on Flickr
LongTravel Install-148.jpg by Monte Nickles Photos, on Flickr
LongTravel Install-149.jpg by Monte Nickles Photos, on Flickr

 

[Blackdawg]

So this isn't much of a "write up" like i normally do. Mostly because..well..i hadn't planned on it at all ha. But since Mike took enough photos figured id mention it and show it off cause...damn..it turned out awesome! I do have to apologize though. I do NOT have near as many photos as my usual write ups do for the detail. But you'll all live.

Basically, this is the rear bumper that I made. I can't take 100% credit as my very good friend Jon came and helped a lot. While it is almost all my design, he did a lot of the welding, and I did the details and cleaning haha Either way, this HurrDurr and FrankenFab collaboration turned out ************* bitchen Like i didn't want to give it away cool. But i did.

Too start, Mike had expressed how he wanted a new rear bumper. Mostly after staring at Frankenstein's *** so much he wanted the swingout and “kitchen” setup. I agreed to give it ago and we hammered out some details.

1. Mike wanted a swing out with a tire mount and two jerry cans as well as the folding table and possibly the HiLift jack on it too.
2. Mike wanted it slimmer then the Badlands bumper he had on it.
3. Plate design of some sort, but a hybrid would be fine
4. wrap around protection
5. reverse lights
6. built in 2'' receiver
7. Tire couldn't be very high
8. License plate mount
   Then there where my requirements

• Be strong. Very strong
• Look damn good while being strong
• Beef as ****
• Be very slim and tight to the body
• 3/16'' plate and ¼'' plate all around
• Beef as ****
• Be stronger then my Elite bumper and better designed
• Have a camp light
• Beef...as..****

So. Pretty standard to do list for a bumper build. So I got busy with coming up with how to make it all happen with the tools and time I had. Of course my time line ended up being VERY far off, but whatever.


I'd be lying if I said I didn't base a lot of my design off of my own Elite rear bumper. Because, come on. It is like one of the best looking a functional bumpers ever made IMO. And seeing as to how Tim is MIA and no longer making them. They are even cooler. But there were many weakness's in mine that I wanted to address, mostly with the swingout and spindle setup.


Here is the original bumper that Mike had. Badlands built! Really its a strong bumper and has served him very well. Ben now has it on his rig. But after looking at it more..it hangs very low. The 2'' lower pipe is completely under the truck a good .5''. So 2.5'' below the body. No wonder he drug it over everything..


SOS extras-9.jpg by Monte Nickles Photos, on Flickr
IMG_3208.jpg by Monte Nickles Photos, on Flickr
IMG_8904 by digirat99, on Flickr


Plenty of room for improvement.


However knowing I didn't have a CAD and laser cutter or anything super fancy to make the super pretty but small beveled edges, I did what most do and bought some tubing. But I bought much bigger then most buy. Most guys that do DIY bumpers go with the classic 5''x3'' square tubing. I went for 6''x3''.


I then cut it half along the edge to make two pieces that where L shaped for the main section. Cut out holes for the reverse lights and the 2'' receiver.


IMG_8907 by digirat99, on Flickr


To mount the bumper I bought brackets made by Eric at Relentless Fab in his DIY section. I bought the spindle and tire mount and lights from him too. The brackets where well made. But, I did not like them for my own design. They stuck out too far and too high. So they where modified. I cut a lot off, about 2'' I think to really suck the bumper up to the truck.


IMG_8915 by digirat99, on Flickr
IMG_8920 by digirat99, on Flickr
IMG_8922 by digirat99, on Flickr


Then I cut holes for the lights and the recovery points. The recovery points tie straight into the .25'' frame mount plates. Mounting the spindle was tricky. I used a square and my eye to get it as close as possible. But really you have to wait till putting on the swing bar to really see how it lines up.


Roughed in..


IMG_8923 by digirat99, on Flickr


Of course many people stopped by to BS it was a fun time


IMG_8925 by digirat99, on Flickr


Then got back to work. I used .25'' wall square tubing to match the 2'' receiver and triangulated it back in a way that half of it was on the face of the 3/16'' plate on the bumper and the other was on the .25'' mount brackets. I also added another section of 3/16'' to the bumper side to make sure any pulling done with this thing would hold.


IMG_8927 by digirat99, on Flickr
IMG_8937 by digirat99, on Flickr


Lovely tac welds..
IMG_8938 by digirat99, on Flickr


Burned it in


IMG_8936 by digirat99, on Flickr
IMG_8931 by digirat99, on Flickr


Then Jon got there. Head of HurrDurr Fab. Where I told him of my vison and what I wanted and how I had roughly planned on how to implement it. He wasted no time and jumped in to help


IMG_8940 by digirat99, on Flickr


I gave Jon the job of cutting the pieces for the side protection and the corners. My Dad stopped briefly to help with me with the swingout tube


IMG_8954 by digirat99, on Flickr
IMG_8956 by digirat99, on Flickr


I had bought just the right amount of tube and there was a perfect full size section to do what I had wanted to originally for the side protection. I did just like I did with main section and had Jon cut in into two Ls.


IMG_8957 by digirat99, on Flickr


As you can see. It not only allows for plate for the under side protection but has the nice top beveled edge. Which makes it stronger and looks a hell of a lot better then straight plate.


IMG_8960 by digirat99, on Flickr
IMG_8961 by digirat99, on Flickr

 

[Blackdawg]

Of course the bed sides aren't right angles, it slopes in. So to make ours bend in. We did a nice whiskey bend. Used the cutoff wheel to cut a line right in the crease of the tubing on the inside. While this usually works great with just a hamer and some wrenches, Jon and I could not for the life of us get it to move. Then I had the idea of putting in the press. Worked great!


IMG_8964 by digirat99, on Flickr
IMG_8966 by digirat99, on Flickr


Now that Jon had a good idea on what to do he went on to finish the two sides while I continuted to work on the swingout. One of the biggest annoyances I have with my Eliter is that the bumper can't handle the swingout when it is open. You can see the bumper flex a lot where the spindle is mounted and the whole passenger side flex. To help keep this from happening, I took 3 of the gussets that came with the Relentless kit and cut them down to stuff up into the bumper to help stop this.


IMG_8968 by digirat99, on Flickr
IMG_8972 by digirat99, on Flickr




Jon then needed help holding stuff as he had finished cutting out the pieces for the side protection. He did an awesome job.


IMG_8974 by digirat99, on Flickr
IMG_8976 by digirat99, on Flickr
IMG_8979 by digirat99, on Flickr
IMG_8980 by digirat99, on Flickr


Jon got back to getting the driver side pieces cut. And I returned to the swing out. I had a bit of an issue as I had made the bumper super tight to the truck. The swingout was now out further then the bumper. So to make the latch work I needed something for the swingout to get clamped too.


After some thought and consultations with Jon and my Dad. Came up with this cool idea.


IMG_8982 by digirat99, on Flickr
IMG_8984 by digirat99, on Flickr


Then added a small leg to the swingout. This stopped to from ever hitting the tail gate as well. The lip on the mount held it from coming out without lifting the swingout just a touch so it would never swing wildly open.


Then the tire mount went on. Mike didn't want the tire super high. Which I agreed with. I often think many swingouts have the tires way too high. He loved how mine sat so we got roughly the same measurements off it for height and got busy. Jon came up with just notching some of the scrap .25''x2'' for the smaller 1.5'' tubing to sit in. Made it very easy to build this.


IMG_8996 by digirat99, on Flickr


Angled towards the truck to match the topper


IMG_8995 by digirat99, on Flickr
https://flic.kr/p/qUQnin
IMG_8990 by digirat99, on Flickr




I used a double lock 2000lb rated latch too. Learned that the hard way with my own bumper.


Then we had a debate. Mike wanted the HiLift on the bumper and Jon was pretty set on doing it. After having my own bumper and using it and modifying my Dads, I just knew the weight would be way too much for the swingout with the single spindle. And it just wasn't fitting in well at all with the flow and design of the bumper. The jerry cans where in the way. So I finally was able to convince them to scrap the idea. Was better to keep the HiLift out of the elements anyways.


IMG_8999 by digirat99, on Flickr


So we moved on to the jerry cans. We repurposed a CBI dual can holder. For the price Mike got it, was hard to beat. Plus, saved us a lot of fab time. We raised the whole thing up to be out of the way of the departure angle.


IMG_9004 by digirat99, on Flickr


With the main stuff done, Jon burned it in as he is a much better welder then I am...i mean..come on. Have you seen his truck?? lol I did the grinding and buffing. Amidst all of this we added 3 bottom plates for underside protection and a support tube from the wings to the frame plates. Sorry for lack of photos


IMG_9005 by digirat99, on Flickr
IMG_9011 by digirat99, on Flickr


I also wanted to cap the ends of the wings cause it just looked like ****..and would make it a tad stronger. Turned out good. Ended up being even smaller though as they ended up being super tight to the truck and had to take into account body/frame flex.


IMG_9012 by digirat99, on Flickr


YAAAAAAAAA!!!!!! SPARKS!!!


IMG_9015 by digirat99, on Flickr

 

[Blackdawg]

Looking like a bumper now!


IMG_9016 by digirat99, on Flickr
IMG_9017 by digirat99, on Flickr


The spindle was out a ways and to make it look better, plus..gusset ..Jon found some scrap 1''x.125'' strap to put on the left side. Made it look much smoother.


IMG_9026 by digirat99, on Flickr


Added a small piece up top to make the corner look better. Also added another gusset to the spindle.


IMG_9024 by digirat99, on Flickr


The gussets did help. It still flexes a tiny bit, but not NEAR as much as mine.


Then we put on a second spring loaded pin latch to catch the bumper from swinging open and hold it at 90º.


IMG_9215 by digirat99, on Flickr
IMG_9028 by digirat99, on Flickr
IMG_9223 by digirat99, on Flickr
IMG_9217 by digirat99, on Flickr


Here is the underside with the final bottom plates in


IMG_9040 by digirat99, on Flickr


Coming together!


IMG_9041 by digirat99, on Flickr
IMG_9043 by digirat99, on Flickr


Then we painted it...well..Mike painted it while Jon and I took a break and discussed how to mount the light to the swingout.


IMG_9049 by digirat99, on Flickr
IMG_9054 by digirat99, on Flickr
IMG_9059 by digirat99, on Flickr
IMG_9060 by digirat99, on Flickr


Which involved Jon getting super hammered once haha


IMG_9063 by digirat99, on Flickr

 

[Blackdawg]

And when the bearing jussssttt doesn't want to go in..and falls out....after you've packed it with grease...awesome..


IMG_9065 by digirat99, on Flickr


because we settled on no HiLift jack, we put two supports under the jerry cans like I originally wanted.


IMG_9067 by digirat99, on Flickr


Then the table got added. Its jut a sheet of aluminum held on with bullet hinges. The hinges are welded to the swingout arm and then the other haft to a 3'' piece of 1/8'' strap. We used flat top allen head stainless bolts to bolt the aluminum to the steel. Cable holds it up when its open and some plastic handle nuts hold it up when its folded up.


The big light thats on the swing out is held in with hose clamps. Jon cut some random tubing we had that the mono pod fit into and attached them in a way to allow the hose clamp to go around the tube and the mono pod. Was quiet clever. The mono pod allows the light to go 65'' up to cast down light on the whole “kitchen” area easily. Its a 5'' led light and is something like 28w I believe. More then bright enough for this and casts a lovely flood pattern. Switch is right next to the light and I coated the switch with liquid electric tape to help keep it water sealed from the Seattle rush.


IMG_9150 by digirat99, on Flickr
IMG_9136 by digirat99, on Flickr
IMG_9137 by digirat99, on Flickr
IMG_9140 by digirat99, on Flickr
IMG_9141 by digirat99, on Flickr
IMG_9142 by digirat99, on Flickr




this shows the switch and how its mounted a bit.


IMG_9145 by digirat99, on Flickr
IMG_9146 by digirat99, on Flickr
IMG_9148 by digirat99, on Flickr


I also added a nice light/mount for the rear licese plate. This is 1''x1'' angle iron 1/8'' thick welded to a 3'' piece of 1/8'' strap. So it makes sort of box with the top open. Up inside it are two small LEDs and the lower section the plate mounts to it and that in turn mounts to the jerry can carrier.


IMG_9209 by digirat99, on Flickr
IMG_9210 by digirat99, on Flickr
IMG_9199 by digirat99, on Flickr


All the wires run to here


IMG_9151 by digirat99, on Flickr


and are placed so that it just rolls nicely out of the way and down into the bumper when it closes.


IMG_9152 by digirat99, on Flickr


The lights in the bumper come on automatically when the truck gets put into reverse. The license plate lights turn on as stock as they get their power from the oem harness.


And the final product..one sexy bumper!


IMG_9106 by digirat99, on Flickr
IMG_9091 by digirat99, on Flickr
IMG_9095 by digirat99, on Flickr
IMG_9110 by digirat99, on Flickr




Over all. Was a fun project but took a ton of work. More then I thought it would.


NO I DO NOT PLAN ON MAKING MORE SO DON'T ASK! LOL!


Seriously though..i don't have any templates or measurements. Was all hand made in the moment type stuff. A true one of a kind! It was fun though and got me thinking about making bumpers for my other truck or my brothers 4runner. We will see what happens some day.


It did turn out awesome though and I can't wait to take lots of pictures of it on trips. It looks great, and I think it'll work just awesome too. All built will basic hand tools and a welder and plasma torch. Took us about 8 days of work straight to make not including the few days I spent on it before Jon got there.


Id say it was worth it though!

Total cost i think for parts and such was about a grand if you're curious. And again..a LOT of work. More then a weekend project anyways haha

 

[Blackdawg]

And when the bearing jussssttt doesn't want to go in..and falls out....after you've packed it with grease...awesome..


IMG_9065 by digirat99, on Flickr


because we settled on no HiLift jack, we put two supports under the jerry cans like I originally wanted.


IMG_9067 by digirat99, on Flickr


Then the table got added. Its jut a sheet of aluminum held on with bullet hinges. The hinges are welded to the swingout arm and then the other haft to a 3'' piece of 1/8'' strap. We used flat top allen head stainless bolts to bolt the aluminum to the steel. Cable holds it up when its open and some plastic handle nuts hold it up when its folded up.


The big light thats on the swing out is held in with hose clamps. Jon cut some random tubing we had that the mono pod fit into and attached them in a way to allow the hose clamp to go around the tube and the mono pod. Was quiet clever. The mono pod allows the light to go 65'' up to cast down light on the whole “kitchen” area easily. Its a 5'' led light and is something like 28w I believe. More then bright enough for this and casts a lovely flood pattern. Switch is right next to the light and I coated the switch with liquid electric tape to help keep it water sealed from the Seattle rush.


IMG_9150 by digirat99, on Flickr
IMG_9136 by digirat99, on Flickr
IMG_9137 by digirat99, on Flickr
IMG_9140 by digirat99, on Flickr
IMG_9141 by digirat99, on Flickr
IMG_9142 by digirat99, on Flickr




this shows the switch and how its mounted a bit.


IMG_9145 by digirat99, on Flickr
IMG_9146 by digirat99, on Flickr
IMG_9148 by digirat99, on Flickr


I also added a nice light/mount for the rear licese plate. This is 1''x1'' angle iron 1/8'' thick welded to a 3'' piece of 1/8'' strap. So it makes sort of box with the top open. Up inside it are two small LEDs and the lower section the plate mounts to it and that in turn mounts to the jerry can carrier.


IMG_9209 by digirat99, on Flickr
IMG_9210 by digirat99, on Flickr
IMG_9199 by digirat99, on Flickr


All the wires run to here


IMG_9151 by digirat99, on Flickr


and are placed so that it just rolls nicely out of the way and down into the bumper when it closes.


IMG_9152 by digirat99, on Flickr


The lights in the bumper come on automatically when the truck gets put into reverse. The license plate lights turn on as stock as they get their power from the oem harness.


And the final product..one sexy bumper!


IMG_9106 by digirat99, on Flickr
IMG_9091 by digirat99, on Flickr
IMG_9095 by digirat99, on Flickr
IMG_9110 by digirat99, on Flickr




Over all. Was a fun project but took a ton of work. More then I thought it would.


NO I DO NOT PLAN ON MAKING MORE SO DON'T ASK! LOL!


Seriously though..i don't have any templates or measurements. Was all hand made in the moment type stuff. A true one of a kind! It was fun though and got me thinking about making bumpers for my other truck or my brothers 4runner. We will see what happens some day.


It did turn out awesome though and I can't wait to take lots of pictures of it on trips. It looks great, and I think it'll work just awesome too. All built will basic hand tools and a welder and plasma torch. Took us about 8 days of work straight to make not including the few days I spent on it before Jon got there.


Id say it was worth it though!

Total cost i think for parts and such was about a grand if you're curious. And again..a LOT of work. More then a weekend project anyways haha

 

[Blackdawg]

Next I built a new bed rack setup and tweaked the LT a bit.

Going to start my new bad rack soon. Which means the old one had to come off.

I will miss it. It was unique and i will miss the lighting setup the most. Still trying to figure out how im going to get roof lighting again..

Anyways, the last photos of Frank with the bed rack. Oh and i actually washed him! With soap and everything! paint looks better then i thought..

BedRackRedo.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-2.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-3.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-4.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-5.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-6.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-7.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-8.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-9.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-10.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-11.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-12.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-13.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-14.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-15.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-16.jpg by Monte Nickles Photos, on Flickr

Even with just the tent off he looks naked..

BedRackRedo-17.jpg by Monte Nickles Photos, on Flickr

All this custom wiring...gone...shame. Was so much work too.

BedRackRedo-18.jpg by Monte Nickles Photos, on Flickr

super naked now!

BedRackRedo-19.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-21.jpg by Monte Nickles Photos, on Flickr

May sell this..or cut a part of it out to reuse. Not sure yet.

BedRackRedo-20.jpg by Monte Nickles Photos, on Flickr

 

[Blackdawg]

This look could grow on me..still doesn't seem right.

BedRackRedo-22.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-23.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-24.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-25.jpg by Monte Nickles Photos, on Flickr
BedRackRedo-26.jpg by Monte Nickles Photos, on Flickr


New bed rack will be moveable. As in the tent will go up and down. I want it low for go fast stuff but still want it up for camping. My idea should work quiet well. Im pretty excited to make it happen.

 

[Blackdawg]

Let the fab work begin.

The new bed rack came around purely because the old one was just too tall. I mean, it wasn't that bad. But for as fast as i wanted to drive and terrain i want to drive. It just made Frank too tippy. Lowering the rack was the obvious solution. But come on. We all still need to pack the truck up too. And i like using the extra annex room with my tent too occasionally, so i needed it to move up and down.

I spent about 3 months thinking about how i was going to do it and finally had enough ideas to give it a try!

I started with 1.25'' and 1.5'' square tubing. I went square because bending round wouldn't have let me get a perfect right angle. In retrospect, i should have just got round tubing for the support legs. Which is probably the main thing id do different if i do it again, and probably will change that later.

New Bed Rack.jpg by Monte Nickles Photos, on Flickr

It took a lot of effort to make the 1.25'' slide into the 1.5'' since square tubing has a seam on the inside so you have to carve that out of the 1.25''...round doesn't have this if found out so would have saved me a **** load of time.

New Bed Rack-2.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-3.jpg by Monte Nickles Photos, on Flickr

But i made them slide just fine.

https://youtu.be/difj8aAQSxw

I then drill holes very precisely to line them all up. I again, ****ed up here on accident. made the holes 13.5'' apart which screwed up which lift supports i was going to use that were 13'' travel and 60lbs of lift.

New Bed Rack-6.jpg by Monte Nickles Photos, on Flickr

this is the layout i used for pins

New Bed Rack-7.jpg by Monte Nickles Photos, on Flickr

i used a spring loaded pin on the driver side legs in addition to the trailer pins. I only did this on one side for a very simple reason. I wanted to be able to operate the bed rack by myself. Can't do that with spring loaded pins on both sides. My arms are long but not that long

New Bed Rack-9.jpg by Monte Nickles Photos, on Flickr

Passenger side just gets trailer pins. 3/8'' and i sleeved all the trailer pins.

New Bed Rack-10.jpg by Monte Nickles Photos, on Flickr

Welded in the pins and sleeves

New Bed Rack-11.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-12.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-13.jpg by Monte Nickles Photos, on Flickr

Then i made some feet out of 3/16"x1.25 strap

New Bed Rack-16.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-17.jpg by Monte Nickles Photos, on Flickr

i placed the legs right next to the last ridge in the bed and we figured out the width for the top tubes. 55.5'' i believe.

New Bed Rack-14.jpg by Monte Nickles Photos, on Flickr

Welded it on and here it is up

New Bed Rack-18.jpg by Monte Nickles Photos, on Flickr

and down.

New Bed Rack-19.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-20.jpg by Monte Nickles Photos, on Flickr

Im liking the height!

New Bed Rack-21.jpg by Monte Nickles Photos, on Flickr

Then there was another screw up. Both my brothers and my fault. He had been helping me which was super fun and cool and id had him cut the upper cross bars. He had literially cut two perfectly 55.5''. BUT when he went to cut the 1.5'' C cut out of the ends, he grabbed the scraped 53'' piece we had left over for the rear bar. I didn't check it and slapped it on the legs and burned it in!

Wasn't untill i set it down next to the front one i realized it was short lol So i patched in some tube to make it right.

New Bed Rack-22.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-23.jpg by Monte Nickles Photos, on Flickr

Then i started the side lift mechanism. I used 1/4'' angle iron, 1/8'' was too weak, on top of the square tubing and a weld on hinge on the passenger side. Then got some 2000lb double locking pull levers to hold it down.

New Bed Rack-25.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-27.jpg by Monte Nickles Photos, on Flickr

 

[Blackdawg]

I think put some 1/8'' angle on the back side on both ends to help it stay where i wanted it. This is another thing id change, probably should have just got some 1/4'' C channel.

New Bed Rack-24.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-26.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-28.jpg by Monte Nickles Photos, on Flickr

Then i started mounting the lift supports. Due to my early **** up i had to make some weird mounts. Not a clean as i had originally planned..but it works. these strust are 80lbs lifting force and 14.5'' travel and won't collapse down below the crossbars like id wanted originally.

New Bed Rack-29.jpg by Monte Nickles Photos, on Flickr

Fronts lower are parallel and the rears got stacked ontop of the leg mounts to sit ontop of a ridge.

New Bed Rack-30.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-31.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-32.jpg by Monte Nickles Photos, on Flickr

At this point i can't believe how freaking hard the struts are to pull down. Like...way way hard. In fact im still not happy with how hard they are. But hopefully they will get easier over time.

Then i started the tent mount cross bars. I would once again sleeve one side to allow it to extend as one side of the tent lifted. And i put bullet hinges inside the tubes.

New Bed Rack-42.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-41.jpg by Monte Nickles Photos, on Flickr

Hinges on the other half

New Bed Rack-43.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-44.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-45.jpg by Monte Nickles Photos, on Flickr

Now the reason i put the hinges inside the tube was for this. So it buts up against the angle iron. Then i just cut off the other side a bit so it bends that particular direction. So for the front i cut off the top part and the rear i cut off the bottom part.

New Bed Rack-46.jpg by Monte Nickles Photos, on Flickr


And the sleeve part

New Bed Rack-49.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-50.jpg by Monte Nickles Photos, on Flickr

Front part gets the sleeve since it lifts last.

New Bed Rack-47.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-48.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-51.jpg by Monte Nickles Photos, on Flickr

And how i cut it to allow it to move

New Bed Rack-52.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-53.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-54.jpg by Monte Nickles Photos, on Flickr

It works!

New Bed Rack-55.jpg by Monte Nickles Photos, on Flickr

 

[Blackdawg]

This is why i sleeved it. It moves, not a ton, but enough.

New Bed Rack-56.jpg by Monte Nickles Photos, on Flickr

New Bed Rack-57.jpg by Monte Nickles Photos, on Flickr

To make sure it always goes back in i put some spring on it and made some butt plates for the tube to meet

New Bed Rack-58.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-59.jpg by Monte Nickles Photos, on Flickr

Added the last cross bars that the tent actually bolts too

New Bed Rack-60.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-61.jpg by Monte Nickles Photos, on Flickr

tested it out

New Bed Rack-62.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-63.jpg by Monte Nickles Photos, on Flickr
Bed Rack by Monte Nickles Photos, on Flickr
Bed Rack 2 by Monte Nickles Photos, on Flickr
Bed Rack 3 by Monte Nickles Photos, on Flickr

It works. For the most part. It isn't perfect, i won't lie. the only part that works unbelievably awesome is the side lift. The rest, not supper easy to do alone. Least not as easy as id like. And its even harder to get down. I basically have to stand on it. But the it goes down just fine. Its also pretty richety when all the way up. I think i should have used 1.75'' round tubing for the outer and 1.5'' round for the inner. Which i think i might do later down the road. But for the most part, im pretty happy it works!

Next i got some 3/4'' round bar and made some handles to help push and pull it up and down. They do help a lot. My dad was home for just a little bit and came over to help torch it and bend it. Sorry i forgot my camera for these next two photos..

New Bed Rack-2.jpg by Monte Nickles Photos, on Flickr
New Bed Rack.jpg by Monte Nickles Photos, on Flickr

Made two for each side and two for the back that are longer.

New Bed Rack-72.jpg by Monte Nickles Photos, on Flickr

Then welded them on!

New Bed Rack-73.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-75.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-74.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-76.jpg by Monte Nickles Photos, on Flickr

Then i welded up everything else and put the tent back on.

But i still had other things to do. One of which was get my skid back on. I just decided to put the stock mount i ripped off back on for the time being. Needed straightening first though...lol

New Bed Rack-33.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-34.jpg by Monte Nickles Photos, on Flickr

welded it back on then realized i had an issue with the skid..again. My LCAs would hit it.

New Bed Rack-37.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-38.jpg by Monte Nickles Photos, on Flickr

so whipped out Jons favorite tool and cut off the corners.

New Bed Rack-40.jpg by Monte Nickles Photos, on Flickr

Can't get mad at RAT productions or whatever. Was like the first skid he ever made and i got it killer cheap..and actually has taken a lot of abuse..

New Bed Rack-39.jpg by Monte Nickles Photos, on Flickr

 

[Blackdawg]

I also got some 16'' 700lb coils. Since i can't run flat bottom spring perches i was worried about the block height of the 18'' coils. didn't want to use them as bumps. Plus they were precomressed a good 1.5-2'' which gave me like barely an inch of down travel. With the new coil, only hav .75'' preload and im at the EXACT height as my old eibachs and 5100s. 14.5'' at the skid. Looks way better too and drives a bit nicer i think.

New Bed Rack-35.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-36.jpg by Monte Nickles Photos, on Flickr

Next i got come CBI ditch light brackets..but not for some lil LED ****. I put my HID Hellas on there haven't wired them up but i know they will work awesome. The Brackets are top quality and easy install too. They are 1/4'' steel if anyone is curious.

New Bed Rack-64.jpg by Monte Nickles Photos, on Flickr

They go right on top of the hood hinge. CBI provides new longer bolts

New Bed Rack-65.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-66.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-67.jpg by Monte Nickles Photos, on Flickr

Some dirt in there....:laugh:

New Bed Rack-68.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-69.jpg by Monte Nickles Photos, on Flickr

You do have to cut the plastic cowling. But not much and thats it really.

New Bed Rack-70.jpg by Monte Nickles Photos, on Flickr

On top of that @552Jrider sent me some clear corners he had just lying around. For FREE. Thanks man! Wow they look good..

New Bed Rack-90.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-88.jpg by Monte Nickles Photos, on Flickr

The hellas don't look great..but not bad. I ordered black covers for them which i think will help since the white is so distracting.

New Bed Rack-89.jpg by Monte Nickles Photos, on Flickr

And truck porn!!

New Bed Rack-78.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-79.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-80.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-81.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-82.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-83.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-85.jpg by Monte Nickles Photos, on Flickr
New Bed Rack-86.jpg by Monte Nickles Photos, on Flickr

And a cool sunset to boot

New Bed Rack-77.jpg by Monte Nickles Photos, on Flickr

And a bad video of the setup. You can see its not perfect. But works enough for me for now.

[video]https://youtu.be/zEiRW5DpZ_A[/video]

Next up: Limit straps and CO2 bottle on swingout.

I also bought an ARB locker today. And need to decide on rear shocks soon with the t100 axle.

 

[Blackdawg]

I redid my swing out. Due to the new bed rack being so low, the 20lb CO2 tank could not fit in the bed right side up for use anymore. So I decided to move it to the swing out and rotate my gas can carrier.

Had to cut off the old one first which was interesting..

Swingout Redo.jpg by Monte Nickles Photos, on Flickr

The rebuilt the original can carrier and added legs to lift it up a bit.

Swingout Redo-2.jpg by Monte Nickles Photos, on Flickr

But the design was flawed. It was too wide, well the basket part that went around the can was. So i scrapped it and started from scratch and decided to make a downward clamp one.

I tried to reuse the original base but ended up just making a new one.

Swingout Redo-3.jpg by Monte Nickles Photos, on Flickr

Got some 3'' 3/16'' strap and the torch out and started bending it.

Swingout Redo-4.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-5.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-6.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-7.jpg by Monte Nickles Photos, on Flickr

Used some 1.5'' .125'' thick angle iron and 1.5'' .125'' thick strap to make the handle clamp.

Swingout Redo-8.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-9.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-10.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-11.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-12.jpg by Monte Nickles Photos, on Flickr

Cut a notch in the bottom for a lock loop and used some of the 3/4'' round bar i had left over to make a simple handle to help pull it down on to the loop. Works awesome!

Swingout Redo-13.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-14.jpg by Monte Nickles Photos, on Flickr

mounted it 3'' up on 1.25'' .125'' square tubing

Swingout Redo-15.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-16.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-17.jpg by Monte Nickles Photos, on Flickr

Then was time to add the CO2. I had the bracket i got with the Wheelers kit and i really liked how easy it was too use and it was strong. So i wanted to reuse it. In order for it to work on my swingout, i had to flip the clamp so it was backwards from how it comes new.

so it looks like this now. The clamp handle pulls away from the gas can now.

Swingout Redo-18.jpg by Monte Nickles Photos, on Flickr

thin **** to weld on..

Swingout Redo-19.jpg by Monte Nickles Photos, on Flickr

Regretably i do not have all the photos i want. Mostly because i literally mounted the gas can on friday morning and fabbed the co2 mount right after and went camping the same day. So was in a major rush. I will update this post once i get the photos because i still haven't painted...well..anything :anonymous:

But i used some 1.5'' .125'' tubing to make the vertical mount and some gussets i had leftover from the rear bumper build to mount the top.

Swingout Redo-20.jpg by Monte Nickles Photos, on Flickr

The bottom is two pieces of tubing and a piece of 4'' by 3/16'' strap for it to sit on. Again, i will get photos later.

Still i am very happy with the location and how it all works. Super easy to get the co2 out. Is a lot of weight on the bumper now, but i take to co2 off when i open the swingout usually. especially for long periods of time. Drives nice though.

And i doesn't look half bad.

Swingout Redo-21.jpg by Monte Nickles Photos, on Flickr
Swingout Redo-22.jpg by Monte Nickles Photos, on Flickr

 

[Blackdawg]

Trip report:

Big Horn Mountains July 4th weekend 2015.

Drove up Shell canyon to an area we are VERY familiar with but drove a new road call Boulder Basin or FS 321. SUPER fun! had a blast on this trail. Definitely want armor for it if you don't have big tires. Even myself and my dad hit our sliders and skids a few times. Nothing bad though. But it goes right to the edge of the Cloud Peak Wilderness area.

Aired down at Ranger Creek

Family 4th Camping.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-2.jpg by Monte Nickles Photos, on Flickr

Top of the hill before we dive down and go back up the shell reservoir road

Family 4th Camping-3.jpg by Monte Nickles Photos, on Flickr

Loved being outside in the hills again for the first time this summer.

Family 4th Camping-4.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-5.jpg by Monte Nickles Photos, on Flickr

This was not a TW meet really. Just my family came, my Mom, Dad, and little brother. Was a hoot and we had fun. While my dad was making a last phone call we tried to teach my mom "pistols" AKA one legged squats haha

Family 4th Camping-6.jpg by Monte Nickles Photos, on Flickr

Still got some truck porn though..

Family 4th Camping-7.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-8.jpg by Monte Nickles Photos, on Flickr

Grant showing mom how to do a real pistol

Family 4th Camping-9.jpg by Monte Nickles Photos, on Flickr

The sun started to set as we hadn't even left town till 4 because of my last minute fabrication project. The wyoming evening light is magical.

Family 4th Camping-10.jpg by Monte Nickles Photos, on Flickr

Grant was my copilot this trip. He had almost brought his own rig but was super glad he didn't in the long run. Would have destroyed the side panels.

Family 4th Camping-11.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-12.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-13.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-14.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-15.jpg by Monte Nickles Photos, on Flickr

Trail is super chill and fun go fast stuff till you dive off the hill. Then the rocks come.

Family 4th Camping-16.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-17.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-18.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-19.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-20.jpg by Monte Nickles Photos, on Flickr

 

[Blackdawg]

The start of the 4lo 1st gear stuff. Was super fun. Wish i had more photos of all the trail and trucks.

Family 4th Camping-21.jpg by Monte Nickles Photos, on Flickr

My mom did not like riding in the truck in the rocks. So she got out and ran/walked along.

Family 4th Camping-22.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-23.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-24.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-25.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-26.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-27.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-28.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-29.jpg by Monte Nickles Photos, on Flickr

Frank walked through everything with ease. The LT front was awesome in the rocks and even better on the rought roads to push fast. The faster i went the smoother it was. The rear wasn't even holding me back much. Super stoked with the truck

Family 4th Camping-30.jpg by Monte Nickles Photos, on Flickr

Right and the end of this tunnel is a big granite slab, and man oh man was it off camber. Would have hated it with the old bed rack.

Family 4th Camping-31.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-32.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-33.jpg by Monte Nickles Photos, on Flickr

this was the only spot i hit my sliders. Came off the ledge to hard, but it was a deep hole!

This photo is taken right after it.

Family 4th Camping-34.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-35.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-36.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-37.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-38.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-39.jpg by Monte Nickles Photos, on Flickr

I love this place

Family 4th Camping-40.jpg by Monte Nickles Photos, on Flickr


Then we reached the large creek crossing and decided to camp at the creek. The only carnage of the whole trip..my mom loosing her footing and scraping her leg.

Family 4th Camping-41.jpg by Monte Nickles Photos, on Flickr

She was all good though.

Our camp spot was super peaceful and beautiful. The bugs where BAD though.

Family 4th Camping-42.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-43.jpg by Monte Nickles Photos, on Flickr
Family 4th Camping-44.jpg by Monte Nickles Photos, on Flickr