Well I've done a bit more to the old monster over the last couple of days. Nothing huge to see but it's all important to the finished product.
The tray is going to be timber decking running length ways. It'll be in 3 sections that will hinge at one end to gain access to all the compartments inside. I've been talking to the owner about using marine carpet to line the storage compartments so things don't rattle around so much. One thing that cropped up was the compartments filling with water. We don't want that, so I've got to make it so the water wont go in the compartments.
Anyway, the first thing I needed to do was to build a lip around the top of the tray so the timber can sit inside it.
I folded up the pieces so they wrap around the top rail, as it makes it look neater. I also added a folded safety edge along the top so there's no sharp edges.
I've made the lip 35mm high, to leave room for the drain channels and timber. Plus I think a bit more height to the tray will help it aesthetically.
The new lip will flow into the back of the cab so it'll all look like it's meant to be there.
It's amazing how long this tray is. The main pieces I've used for the lip are 2400mm long, yet I still have to fold up another piece just over 500mm long to get the length I needed : )
I've tacked the straight pieces on first. I'll make the corner pieces separately as curving the safety edge is tricky.
I've got to make recesses next to the engine lid hinge mounts so the hinge pins have room to be slid out when needed.
By making the rail cover part a bit deeper it can be used to mount the engine lid seal along the top.
The arty shot : )
Next thing I did was make the corner pieces.
Where the lip meets the cab needed to be boxed up so the timber can be in a straight line all the way along the cab, rather than having to taper into the corners.
With that done it was time to start on the drain channels. I started by fully welding the new rail pieces to the top supports that run across the tray, as the drains will cover these so I wont be able to get to them once the drains are on.
Again I folded up some 1.2mm with a safety edge to make the channels. That way when someone reaches in to grab something or work on something in one of the 3 sections they wont cut themselves on the steel edge.
I've only made the drain for the middle section, but you see how it's going to work. Each cross drain will have a hole drilled straight through it to and a tube welded in that will run to underneath the car. I'll do the same in each rear corner. Should work fine and be easy enough to make. I can't imagine this car getting driven too much on really rainy days but it can't hurt to plan ahead as much as possible.
Once all the various bits and pieces are fabricated and fitted I'll then have the fun task of a massive weldathon blending it all in, but I think it'll look pretty cool. The lids for each of the 3 compartments will just be 1.2mm zinc with a 10mm folded edge that will overlap the lips in the tray. The timber decking will get screwed to the 3 steel lids and they'll all have gas struts to support them. I still have to nut out the hinges and catches yet but I'm not at that stage yet so haven't been thinking about it. i will soon though so hopefully something will pop into my pea brain : )
Edited by dirtbag, 22 April 2012 - 10:22 AM.
