Trucking along on this build. I went aluminum, 3"x0.25" angle for the perimeter frame and boxed for the bed to frame mounts, 2x2x0.120" square tube for the stringers and bulkhead.
1/8" sheet for the inner fenders, body work, and boxes.
I've got some springs coming to be installed on the rear four bed mounts to allow for some flex in a sort of semi-floating design.
This is as far as I've gotten so far, but this weekend will be two additional stringers sandwiching the center mounting brackets (closest to the camper tie-downs), some stops on the bulkhead for the camper to sit against, and the rear bed-sides/tailights.
Probably won't get any boxes or the upper, folding bedsides done before Northwest Overland Rally next week, but the concept will be pretty clear and the bed will certainly be useable (and legal).
I just used 3/4" marine ply set into the perimeter frame as a bed floor. It's just bolted to the stringers, so it's easily removable for access to repair items (fuel pump and tank specifically) below the bed, which is a huge plus for me. I ordered some roll-on rubber from Amazon that I'll completely coat the ply with to seal it up from the elements and give the camper a bit more "squish and stick" sitting on the bed. My hope is that it sits well enough that I can eliminates the large heavy stall mat I've been using.
Its an ongoing learning experience working with the aluminum. This is definitely the most complicated fabrication project I've taken on, compounded by working with a new, more difficult material. It's fun though and other than being slow I'm pretty happy and confident in the results. I'm impressed with how well the brake I built works and I'm looking forward to making more use of it.
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Edited by pawleyk, 19 June 2016 - 04:21 PM.
