NewHilux.net

Draw the required angle(s) on the floor or a work bench in chalk mate then sit the material against it, when It lines up tak it in place, Even do a whole headboard lay out on the floor, a lot easier than how you are trying to do it in the pic, alternatively get a bevel gauge tak the uprights to the tray, use the bevel gauge on the uprights and tak when the correct Angel is achieved. But best way is a floor or bench (if big enough) layout


Sent from my iPhone using Tapatalk

I used ply templates when doing mine. couple sheets of 7mm ply and cut out templates of headboard and tail light assembly to test a few and get the one I wanted [emoji106]

Thanks for the tips guys. Def gonna do some templates for the tail lights.
Never really done a lot of metal work so it's funny when you don't know what you don't know.

Got this far today after a lot of interruptions.

I reckon all drop saws do that i had the same issues, it was fun trying to fill 5mm gaps with weld
I found if i used heaps less pressure on the saw it didnt run out as much just took longer to cut it all up.

Its coming along nicely just make sure all your welds are sealed on your headboard or sikaflex them up after. I noticed a few weeks back my headboard was leaking water out of a bottom weld, drilled a few drain holes and dumped around 5l of water out of the bloody thing

I think you might be right about the saws. A mate said he used to have one where he had to push on the guard rather than the handle cos it kept sliding away in the cut. You just gotta trust the guard... I suppose I have a spare hand if it fails. [emoji52]
The saw I have doesn't have a support on the other side, it just pivots around one axle (left side) rather than having another pivot point on the right side of the cutting disc. That can't help the stability, but one gets what one pays for.

Good call re the sealing. Will double check the welds.

Thanks to you and everyone else who's posted here for the tips and tricks

Following this closely. Looking good fish !!!

looking awsome man good stuff can't wait to see it all finished

Got some timber for the tray bed and head board yesterday.

90x19mm
Also got one big slab for the back board.

Started on the spew rails too.



Sent from my SM-G901F using Tapatalk

Got the rails finished.


I got the sides and tailgate all folded up at metalland.


Just trial fitting backboard


Lotsa little things to do (and some big things). Hard part is getting a run at it

Sent from my SM-G901F using Tapatalk

Everybody please take a moment to remember Gary the grinder. Gary had a workplace accident (fell off the back of the ute) and snapped in half.

RIP Gary. Gary's replacement is on the left.



Dodgy old Bunnings Ozito grinder kept on keeping on for over 10 years.
The new Bosch grinder is so good though, well balanced, and so little vibration compared to the El cheapo unit. A lot quieter too.

Rip gary! I feel your pain, I had to retire Walt my Dewalt drill earlier this year after many years of service.

Sent from my SM-N920I using Tapatalk

Built and tacked the lower tailgate onto the upper tray. The low part sits out a bit to take the force from any lack-of-talent-reversing incidents rather than the face of the drawer.



The middle notch is for access to the dead man catch on the drawer. This catch is there to hold the drawer closed even if you don't engage the handle /locks.



Progress slowly happening...

Next thing is to make the tail light surrounds

Sent from my SM-G901F using Tapatalk

Tail light surrounds tacked in



Put the lights in for sh1ts and giggles



Got one reversing lamp (3 inch square), thinking of getting a second one for the other side. Thinking about adding a switch so you can turn them on, like an extra set of work lights, not just in reverse.

Sent from my SM-G901F using Tapatalk

Finished the tail light surrounds.





Added an angle bit across the tailgate to protect the end of timber floor when it's in.


Sent from my SM-G901F using Tapatalk

Keep up the good work mate

Sent from my SM-N920I using Tapatalk

TOYZX wrote:Keep up the good work mate

Sent from my SM-N920I using Tapatalk

Thanks mate. Dragging on a bit but you get that in the big jobs

Sent from my SM-G901F using Tapatalk

Bro my took months! Mostly because I had a hernia repaired mid build but hey! Slow and steady wins the race! I helped a mate build one last year, we rushed it a bit and now he wants to add to it! Take ya time man!

Sent from my SM-N920I using Tapatalk

On the back of your headboard weld some Upside down L shape lugs every 300. You'll be surprised how handy they are with tie down. Did this on my old tray.

06lux wrote:On the back of your headboard weld some Upside down L shape lugs every 300. You'll be surprised how handy they are with tie down. Did this on my old tray.

Do you mean on the cabin side? I was planning to do some at the top for future things (tent rack, tray lights, led driving light mounts).


Sent from my SM-G901F using Tapatalk

Here's the progress I made today.
Put angle end caps onto each of the sides.




Then started tacking the hinges into place.







Beginning to look like a ute tray.

Sent from my SM-G901F using Tapatalk