Squall Line's Frontier build

[Squall Line]

This is partially a copy and paste from club frontier, but I have added the fridge and winch line install. These were completed two weeks back.

Total Chaos upper control arms
Radflo front coilovers; 3"lift and the heavier springs
Sway a way rear resi struts
PRG adjustable shackles
Deaver add a leaf
DIY 2" Body Lift
Procomp MT 285/75/16 / Procomp 7089 in 16x8
Shrock front bumper
Superwinch EP9 winch
Viking delrin rollers and 3/8" winch line
In-cab winch wiring with arming switch for both inside/ outside
Cobra cb with radio shack whip antenna
Notched fenders
Relocated body wiring harness
Engel MR040 fridge

In a few of the pictures, I had the Maxxis Bighorns in 255/85/16 prior to the body lift. Future plans call for building sliders and a rear bumper. A rtt is in the future plan, but the rig dose just fine with ground camping for now.I am considering dropping the body lift, and getting a full replacement leaf pack. I am still undecided on which set of tires I would like to run long term. Aesthetically, I like the procomps, and I have a full set with a spare. The 255s are possibly more economical, but only a marginal difference. I do think they are more in line with overlanding, however (less noise and rubbing in extreme flex). I need to do some back to back tests on fuel economy...

http://img.photobucket.com/albums/v107/RaceBred/P3200151.jpg
http://img.photobucket.com/albums/v107/RaceBred/P3200153.jpg
the solenoid wiring had to be extended for the winch plug/ in-cab wiring
http://img.photobucket.com/albums/v107/RaceBred/P3210162.jpg
http://img.photobucket.com/albums/v107/RaceBred/P3240175.jpg
http://img.photobucket.com/albums/v107/RaceBred/P3240176.jpg
http://img.photobucket.com/albums/v107/RaceBred/P3240177.jpg
http://img.photobucket.com/albums/v107/RaceBred/P3240178.jpg
255/85 Bighorns on the left, 285/75 Procomps on right
http://img.photobucket.com/albums/v107/RaceBred/P3240179.jpg
prior to body lift and notching, rubbing was extreme.
http://img.photobucket.com/albums/v107/RaceBred/P6100013.jpg
after the 2" body lift

[Squall Line]

http://img.photobucket.com/albums/v107/RaceBred/P4280007.jpg
watertight gland at rear of cab for wiring (cb at the moment)
http://img.photobucket.com/albums/v107/RaceBred/P4300011.jpg
rivnuts for external speaker
http://img.photobucket.com/albums/v107/RaceBred/P4300012.jpg
http://img.photobucket.com/albums/v107/RaceBred/P4300015.jpg
http://img.photobucket.com/albums/v107/RaceBred/P4300016.jpg
relay for the driving lights
http://img.photobucket.com/albums/v107/RaceBred/P5010019.jpg
tapping for in-cab winch control
http://img.photobucket.com/albums/v107/RaceBred/P5010021.jpg
http://img.photobucket.com/albums/v107/RaceBred/P5010022.jpg
http://img.photobucket.com/albums/v107/RaceBred/P5010023.jpg
http://img.photobucket.com/albums/v107/RaceBred/P5010025.jpg

[Squall Line]

http://img.photobucket.com/albums/v107/RaceBred/P5010027.jpg
http://img.photobucket.com/albums/v107/RaceBred/P5010028.jpg
http://img.photobucket.com/albums/v107/RaceBred/P5020031.jpg
rivnut for body harness relocation
http://img.photobucket.com/albums/v107/RaceBred/P5020032.jpg
notched fender

Engel MR040 mount Fab:

http://img.photobucket.com/albums/v107/RaceBred/PA070012.jpg
The previous rear seat setup (please excuse the mess)

http://img.photobucket.com/albums/v107/RaceBred/PA070013.jpg
the fridge

http://img.photobucket.com/albums/v107/RaceBred/PA090016.jpg
mockup

http://img.photobucket.com/albums/v107/RaceBred/PA090015.jpg
not my best work ever, but it'll hold

http://img.photobucket.com/albums/v107/RaceBred/PA090017.jpg

http://img.photobucket.com/albums/v107/RaceBred/PA090019.jpg
drilled the holes to accept the 3" quick fist, or smaller ones stacked.

[Squall Line]

http://img.photobucket.com/albums/v107/RaceBred/PA090020.jpg

http://img.photobucket.com/albums/v107/RaceBred/PA090021.jpg
Brackets for the turnbuckles

http://img.photobucket.com/albums/v107/RaceBred/PA090024.jpg
In the truck. The carrier is notched on the left end for the power plugs.

----

Viking synthetic winch line and delrin rollers.
Here is the 80' of 3/8" line going on. I painted the fairlead with plastikote spray on bedliner. If you look closely, the area I masked off is visible. I choose to leave the friction surface on the rollers bare for longevity concerns. I have a 3/8", 50' extension as well.

http://img.photobucket.com/albums/v107/RaceBred/PA030008.jpg
fresh from sierra

http://img.photobucket.com/albums/v107/RaceBred/PA030009.jpg
part of the reason for the upgrade-- stock roller damaged after a severe side pull to fix bad decision making... :)

http://img.photobucket.com/albums/v107/RaceBred/PA100027.jpg
Line going on

----

AT fuel can mounts
I finally got these mounted up. It involved drilling two more holes in the mount. I decided on this location based on minimizing bed space lost, and due to the hump on the front drivers side bed for the fuel filler. I am planning on building a box to mount the second battery under the passenger side rack.

http://img.photobucket.com/albums/v107/RaceBred/PA030001.jpg

http://img.photobucket.com/albums/v107/RaceBred/PA030002.jpg

More to follow.I hope you all enjoyed the pictures. Any suggestions would be appreciated!

Eric

[Squall Line]

I will post up some pictures soon with the fridge installed, of the switches, and with the Wavian fuel cans in (just received yesterday :) ) as soon as possible...

[articulate]

Niiiiiice.........

:)

[Creek]

Sweet Rig!!!

[mcm4090]

Impressive truck!

[Streakerfreak]

Fantastic Frontier! I really like that bumper!

[CoastalDefender]

Excellent truck!!! :archaeolo

[Squall Line]

Thanks for all of the kind words. I know I have been following a few of your builds as well, and have gotten plenty of inspiration for this one. Here are some photos I have been meaning to add:

Cooler installed on mount:
http://img.photobucket.com/albums/v107/RaceBred/PA280015.jpg

http://img.photobucket.com/albums/v107/RaceBred/PA280019.jpg

http://img.photobucket.com/albums/v107/RaceBred/PA280020.jpg
I still need to make a canvas cover for the back wall. The mount is really a compromise in this truck, but the cooler and position was chosen so that the passenger could reach it when driving, and so that access from the door is just as easy. A 45 would have been a bit harder to open, effectively putting a wall between the user and fridge from one side when open... If I had known that the hinges on the 35/45 could be moved to the sides, I may have gone that route. They are slightly slimmer, and would afford more room for the seat. As it is, I am 6'0 and have plenty of adjustment in the seat. I just cant lay it back for a rest. I need to tweak the bracket a bit as it dos'nt seem to be sitting exactly level, but that is not a big deal to fix.

Wavian fuel cans in the AT mounts:

http://img.photobucket.com/albums/v107/RaceBred/PA280016.jpg

http://img.photobucket.com/albums/v107/RaceBred/PA280017.jpg
I am not 100% sure on the position, but I think they will look more at home when a RTT is installed on the reward section of the bed. I do like the upright mount for ease of refilling at the pump.

Switches:
http://img.photobucket.com/albums/v107/RaceBred/PA280021.jpg
I never posted a fished picture of these... The far left is a momentary in/out for the winch, the center switch is for the driving lights (the lower position is unused, but will be for back up lights with the new bumper), and the far right switch arms the in-cab winch switch and the socket on the bumper (over cautious, but to prevent vandalism). I separated the winch controls with the light switch to prevent accidental engagement of both at the same time.



The next step is the rear bumper fab. I will post in-progress pictures of that once I get rolling on it. The parameters are as follows: Integrated receiver, wrap around rocker protection, compact form, backup lights and recovery points.

I am still trying to decide:
-if I should remove the body lift, and go back to the 255s (or go 265/75r16 on the current wheels) -- this affects mounting height...
- if I should incorporate a carrier for the spare (dependent on tent mounting/ storage space desired)
- If I should make room for a rear winch/ fairlead
- If I should notch the bed sides for the wrap-arounds

The ultimate goal is a stronger rear end with better departure angles. The body lift amplifies the low hanging stock bumper and receiver as is.

'Till next time,
Eric

[Backwoods Rambler]

Very cool build

[mcm4090]

I love where you mounted the fuel cans.

What are you using for a spare tire mount?

[Squall Line]

I love where you mounted the fuel cans.

What are you using for a spare tire mount?


you can see it is this picture : http://img.photobucket.com/albums/v107/RaceBred/PA070013.jpg

I ordered a bunch of brackets from McMaster for the uni strut system. I threw it together in about 5 minutes when I was heading out of town. I used metric bolts and a spare set of wheel locks for a bit of security. It is fairly stout, but dose flex the bedside on big hits. It is just a temporary thing until I get a tent/ camper. You can see the high lift mount on the left side in the image as well. That was made from the same type of brackets. If you want more specifics, I can take some closeups/ get part numbers.

[Squall Line]

A few random pictures of the truck from the last north GA trip I just remembered about...
http://img.photobucket.com/albums/v107/RaceBred/n548885407_4390746_5533.jpg

http://img.photobucket.com/albums/v107/RaceBred/n548885407_4390807_6585.jpg

http://img.photobucket.com/albums/v107/RaceBred/n548885407_4390763_7027.jpg

[AlabamaWill]

hey Squall Line were in GA are do you live; I just moved to Macon. I dont know any place to go camping or wheeling.

[Squall Line]

Will: I actually live in north Florida. My girlfriend and I wanted to see the mountains that weekend, so we went for a little drive... We explored the Oconee and Chattahoochee national forest among other things.

---
I have started working on the bumper. Here are the pics so far. Progress may be slow, but it should be interesting to see it come together.

http://img.photobucket.com/albums/v107/RaceBred/PA300001.jpg
not a very good before picture, but I forgot to snap one earlier

http://img.photobucket.com/albums/v107/RaceBred/PA300003.jpg
a lot of low-hanging junk

http://img.photobucket.com/albums/v107/RaceBred/PA300004.jpg
cleared out

http://img.photobucket.com/albums/v107/RaceBred/PA300006.jpg
4X6 3/16" steel

http://img.photobucket.com/albums/v107/RaceBred/PA300007.jpg
more mockup

http://img.photobucket.com/albums/v107/RaceBred/PA300008.jpg

http://img.photobucket.com/albums/v107/RaceBred/PA300010.jpg
working on the brackets 3x3", 1/4" steel angle

http://img.photobucket.com/albums/v107/RaceBred/PA300011.jpg
needs a little tweaking

http://img.photobucket.com/albums/v107/RaceBred/PA300015.jpg
brackets done

I don't know when I will be able to work on it next, but I will post progress as it comes. I have a pretty neat idea for the tire carrier, so I will have to see how that works out. I am not sure on the wrap arounds just yet, but that should be fun to figure out...

Eric

[Squall Line]

Finally got some time to work on this some more. I have the hardware coming in tomorrow for the tire carrier from mcmaster. I will be welding in ports for use as an air tank (calculated roughly 5.1 gal). I will be doing a slight notch of the bed as well, and wrap around protection. It should really start falling together in the next few days.

http://img.photobucket.com/albums/v107/RaceBred/PB040001.jpg
tacked in position

http://img.photobucket.com/albums/v107/RaceBred/PB040002.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB040003.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB040008.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB040010.jpg
I notched the brackets for more surface area, and to pull the bumper in and up a bit.

http://img.photobucket.com/albums/v107/RaceBred/PB040014.jpg
grinding the curve into the end caps




http://img.photobucket.com/albums/v107/RaceBred/PB040011.jpg

[soonenough]

Nice work! Those welds look like they were done with TIG, but the only welding equipment I saw in the pictures was a Linclon MIG setup. If you did MIG weld those, can I come by for some lessons sometime? :D

EDIT: nevermind, I just noticed the cord for the TIG torch on the bench in that last picture.

[4Rescue]

That is one good lookin truck mate, and I am admitedly not the biggest Nissan fan. Love the 255/85's, is there any truck they DON'T make look expedition worthy :) Nice build now we need some action shots of her out in the dirt and rocks.

Cheers

Dave

[Red Zebra]

Nice work! Those welds look like they were done with TIG, but the only welding equipment I saw in the pictures was a Linclon MIG setup. If you did MIG weld those, can I come by for some lessons sometime? :D

EDIT: nevermind, I just noticed the cord for the TIG torch on the bench in that last picture.

Some people weld....others are welders. He's definitely the latter! :bowdown:

[bigdog]

great looking rig. My shrockworks bumber should be here by x-mas, can't wait. Love the AT mount location, seems like they are up and out of the way, but not blocking your view. And that tire size is very interesting. I went with the 295/75/16 to get the 33+" but that winds up being a little wider then I would have liked. Interested to see how that rear bumper turns out.

[Squall Line]

Thanks for all of the comments! I have been trucking along on the bumper the last two days and finally have something to show for it.
http://img.photobucket.com/albums/v107/RaceBred/PB060001.jpg
the only fab work I have outsourced so far: I had the local metal shop punch out the holes for the receiver. In hindsight, I would have been better off with a small cutoff wheel and drilling the corners...

http://img.photobucket.com/albums/v107/RaceBred/PB070004.jpg
I ditched the end cap that was there, and decided to give this setup a shot for the tire carrier. The bushings are just for mock up; the real piece is still on the way.

Got the hitch on today:
http://img.photobucket.com/albums/v107/RaceBred/PB080014.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB080015.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB080017.jpg


http://img.photobucket.com/albums/v107/RaceBred/PB080020.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB080021.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB080022.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB080025.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB080027.jpg

[Squall Line]

http://img.photobucket.com/albums/v107/RaceBred/PB080028.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB080030.jpg
NPT port for the air chuck. The weld was giving me some grief, so I welded up the backside to ensure no leaks. I should have cleaned it better before welding.

http://img.photobucket.com/albums/v107/RaceBred/PB080031.jpg
New endcap tacked up.

http://img.photobucket.com/albums/v107/RaceBred/PB080032.jpg
Ground the shackle mounts to fit flush without having to grind that weld.

http://img.photobucket.com/albums/v107/RaceBred/PB080036.jpg
Where it will sit.

http://img.photobucket.com/albums/v107/RaceBred/PB080037.jpg
Bearings mocked up.

I left off here tonight. Tomorrow I am going to get the endcaps ground flush, then weld em on. I need to throw two more ports on the back side for onboard air in the future. Hopefully I can get the quarter protection on and the bed cut tomorrow, and call it good until the tire carrier part gets here. Just a note on the shackle mounts: I choose that location based on strength, and having little real estate with the tire carrier. They give up a small bit of departure angle, but they are no lower than the shackles which are less than a foot forward. Any comment or criticism is appreciated! It's been a long day :beer:.

Eric

[Squall Line]

Here is the work from yesterday. I am on to the wraparounds today.

http://img.photobucket.com/albums/v107/RaceBred/PB090013.jpg
Ports

http://img.photobucket.com/albums/v107/RaceBred/PB090016.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB100027.jpg
at work

http://img.photobucket.com/albums/v107/RaceBred/PB100031.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB100033.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB100039.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB100040.jpg

[bigdog]

now that's an integrated receiver hitch!

[Squall Line]

I finally got some work done on Sunday and today. The bed is cut, and sliders tacked in place. I need to finish-weld em, and add another brace to the frame on the back end.

http://img.photobucket.com/albums/v107/RaceBred/PB160002.jpg
cut

http://img.photobucket.com/albums/v107/RaceBred/PB160004.jpg
masked and painted

http://img.photobucket.com/albums/v107/RaceBred/PB180006.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB180007.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB180011.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB180012.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB180013.jpg

More to come after Thursday (hopefully!). The bushing for the swing-away finally came today... I still cant decide if I want to add a top rail to the bed sliders (like many on this site). I like to look and protection, but there is no clean way to do it as far as angles go.

Eric

[hovenator]

Awesome truck....Great welding and pics to prove it.....That is going to be one sweet set-up! You do really great work.

:bowdown:

[mcm4090]

Nice work. Do you know much the bumper will weigh?

[The BN Guy]

Excellent! Another bed cut! Not too many of us around.

[Streakerfreak]

AT fuel can mounts
I finally got these mounted up. It involved drilling two more holes in the mount. I decided on this location based on minimizing bed space lost, and due to the hump on the front drivers side bed for the fuel filler. I am planning on building a box to mount the second battery under the passenger side rack.

http://img.photobucket.com/albums/v107/RaceBred/PA030001.jpg

http://img.photobucket.com/albums/v107/RaceBred/PA030002.jpg



I'm curious as to how exactly you mounted those in there like that...unless I missed something in the tread?

Are they just held in there with bolts on the back and side? How are the bolts mounted in the side? Are they holding up okay suspended like that with Cans and fuel in them?

I like this placement and might steal your idea depending on how they are mounted. Its about time to ditch the canopy due to the damage it received in Death Valley and I will need a better place to mount my holders.

[Squall Line]

Streakerfreak: they are mounted to the stock utilitrack rails using unistrut (commercial conduit mounting system) nut plates. There are two 1/4" bolts on the long rail, and one in the corner next to the toolbox. They are extremely stout; the rails are rated for a 200lb load per cleat... To test, I stood and jumped on the empty mount (160lbs) and there was no movement or cause for concern. I would have mounted them on the floor in that location, but the hump for the fuel filler prevented that. HTH

mcm4090: I am not sure yet on the weight, but it is definitely getting up there. I know it is not heavier than the front yet, which weighs 120 for the whole package... The tire carrier is going to add some mass for sure though. I guess that is the price to pay for functionality and bombproof peace of mind.

Thanks to everyone for the comments and following along!

[Squall Line]

http://img.photobucket.com/albums/v107/RaceBred/PB200001.jpg
starting to look pretty crazy

http://img.photobucket.com/albums/v107/RaceBred/PB200003.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB200004.jpg
supports tacked

http://img.photobucket.com/albums/v107/RaceBred/PB200006.jpg
and welded

[Squall Line]

Not too much in the way of progress, but I have finally closed the chapter on the bumper itself, and am working on the tire carrier. I am hoping to have a big weekend and finish it all up. I have exams in a week, and it would be good to have the truck ready for a December/ new years trip...

http://img.photobucket.com/albums/v107/RaceBred/PB260001.jpg
bushing for swing-away and threaded insert for the gas strut

http://img.photobucket.com/albums/v107/RaceBred/PB260003.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB260004.jpg

Eric

[ToyFamily]

Nice build! I like the rivnuts

Nick

[Squall Line]

Thanks again for all of the comments.

Nick: you probably wouldn't know it, but I stopped by the shop last spring to pick up the bumper (truck looks quite a bit different now). Impressive work coming out of there!


I am hoping to have it done today or tomorrow...Here is a quick update:
http://img.photobucket.com/albums/v107/RaceBred/PB280003.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB280005.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB290007.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB290008.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB290009.jpg

http://img.photobucket.com/albums/v107/RaceBred/PB300010.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC020003.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC020004.jpg

[hovenator]

Looking really good. Your truck is really sweet. Great job on all the mods.

[adrenaline503]

Are you a DC?

[Squall Line]

Are you a DC?
No, but I work for one. I am essentially a non rate attached to the RO in town until graduation (CSPI).Do you have any affiliation?


I need to grind a few things, put on the backup light brackets, and then it is ready for paint. Here is the work from yesterday:
http://img.photobucket.com/albums/v107/RaceBred/PC040001.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC040002.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC040003.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC040004.jpg

[adrenaline503]

I am an ET2, thats very nice work you do.

[Squall Line]

adrenaline503: maybe we'll cross paths some day. I would love to see that ute bed in person.

I am pretty much in the last stage of the bumper project. I need to let the paint dry, then get the lights wired up. Here are the pictures:

http://img.photobucket.com/albums/v107/RaceBred/PC060001.jpg
wire-brushed and ready for paint

http://img.photobucket.com/albums/v107/RaceBred/PC060003.jpg
in primer

http://img.photobucket.com/albums/v107/RaceBred/PC110006.jpg
painted- cleaned up the welds with the grinder prior

http://img.photobucket.com/albums/v107/RaceBred/PC110007.jpg
latch detail

http://img.photobucket.com/albums/v107/RaceBred/PC110008.jpg
reinforced the plate for the latch (it was flexy)

http://img.photobucket.com/albums/v107/RaceBred/PC110009.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC110010.jpg
backup light brackets

http://img.photobucket.com/albums/v107/RaceBred/PC140011.jpg
in primer

http://img.photobucket.com/albums/v107/RaceBred/PC140012.jpg
done

------

I got the pieces for the next project. I forgot to mention that I picked up a camping lab tent a few weeks back... The pieces are just sitting in place, but this will be the basic form...

http://img.photobucket.com/albums/v107/RaceBred/PC110005.jpg

-Eric

[Streakerfreak]

Looking good! I am closely watching your build. I look forward to see what you have in store with your bed.

[articulate]

That's one studly hunk-o-metal.

I like the hinge.

[hovenator]

Can we see a finished pic of the tire carrier, etc. all painted up? Please? Sweet build by the way.

[Squall Line]

I will get some pictures of it up tomorrow. Thanks for all of the support.

On a side note, I put in a huge order today from Mcmaster and Del City (my bank account is hurting :mad: )... I have a ton of hardware and electrical stuff inbound to get the rig ready for the new years trip. I am finally going to isolate that aux circuit, and install the 2nd battery. I have the hardware for the rack coming as well, and will be putting together a better solution for the highlift jack in the bed that will incorporate with the rack.

Eric

[MisterTinkle]

I really like your bumper design. Mind if I poach ideas from it?

[Squall Line]

Mister: go for it. The only idea that is really of my own is the hinge, but everything else I took from watching other builds. Feel free to use anything... I have been a bit slow to get pictures, but I will see what I can do after work before dark.

[Squall Line]

Here are some pictures of everything buttoned up. I had to order a steel end for the gas strut as the nylon one stripped out. I need to run the wires for the backup light, tag light, and trailer harness. Those parts should be in today.


http://img.photobucket.com/albums/v107/RaceBred/PC180001.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC180002.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC180004.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC180005.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC180006.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC180007.jpg

http://img.photobucket.com/albums/v107/RaceBred/PC180008.jpg

[MisterTinkle]

Eric, look nice. Great work. I like the integrated receiver and the side rails/sliders. Thanks for your permission to use some of your design ideas!
Sam

[RakkasanFA]

Looks really awesome. I am about to order a rear KMA bumper myself but without the tire carrier. Your truck looks great!

[hovenator]

Looks fantastic......Makes me wish I had bought a Frontier!

[Squall Line]

I finally got the rack built and tent on! The project is finally winding down for now. I need to run some battery cables, install the switch and VSR, then do some accessory wiring tomorrow. Next week I will be going on a week long trip to Nashville for new years, then east to the Smokies, Carolinas and anywhere else we end up.

Here are the pictures:

http://img.photobucket.com/albums/v107/RaceBred/PC210011.jpg
Bracket drilled, the high lift will mount on the stud below

http://img.photobucket.com/albums/v107/RaceBred/PC230013.jpg
upright

http://img.photobucket.com/albums/v107/RaceBred/PC230014.jpg
mocked up

http://img.photobucket.com/albums/v107/RaceBred/PC230016.jpg
capped the ends

http://img.photobucket.com/albums/v107/RaceBred/PC240019.jpg

http://img.photobucket.com/albums/v107/RaceBred/IMG_0193.jpg

http://img.photobucket.com/albums/v107/RaceBred/IMG_0194.jpg

http://img.photobucket.com/albums/v107/RaceBred/IMG_0196.jpg

http://img.photobucket.com/albums/v107/RaceBred/IMG_0201.jpg

[bigdog]

that's cool, I like the way you've got it up and out of the way so you've still got a truck bed. And I assume that the tent easily disconects for when you are not camping.

[RakkasanFA]

So... when are you mass producing these? LOL

[articulate]

Great idea with the tent mounts, the height, etc. Are those brackets aluminum?

Are you okay with the water cans (seemingly) blocking the access to the toolbox?

[mcm4090]

So... when are you mass producing these? LOL
:ylsmoke:

If you don't mind me asking, why did you decide to mount it high above the bed?

[Squall Line]

bigdog: it is 4 nuts to take the tent off of the rack... Should only take a few minutes, but a second person is a necessity for lifting it off.

RakkasanFA: I probably wont be making any more... I am into it less than $100, but that three days of labor is the expensive part.

articulate: They are aluminum. I wanted to keep the weight down, and not have to worry about corrosion as much. Toolbox access is not as easy as before, but I can get my recovery bag (biggest resident) out with little fuss. I may drop the fuel cans horizontal, and lower with a fabricated bracket. I mounted them as is because it was the easiest at the time.

mcm4090: it keeps a lot of the bed space usable while keeping a majority of the tent out of the wind stream. It is a compromise, but one I wanted overall. If you put it on a convential rack, you get a high CG and a good 1-2mpg hit, but retain bedspace. Down low is good, but I didnt want to loose a big chunk of cargo space. I may close off the racks with sheet aluminium to make some secure/ weather resistant storage.

Thanks for the comments,
Eric

[jim65wagon]

I really like the attention to detail; specifically the body contoured sliders, the out of the way air chuck, and super sturdy tire carrier.

[articulate]

Eric,
Something I'll totally recommend is adding some LED strips to the inside of your roof tent. Check out this thread. (http://expeditionportal.com/forum/showthread.php?t=18418) It's cheap, effective, really cool, really useful, and LEDs are efficient.

Sweet build you've got going on. Really sweet build. Keep on going.

[Squall Line]

Thanks for the idea Mark. I have some old stock of bridgestone light guide laying around... I am thinking of putting some on the internal frame. Think low draw LED coupled with acrylic tube with a fiberoptic strip inside...

Here are some pictures of the new-years trip. My girlfriend and took a rough route through Alabama to Nashville for new years, on to Knoxville, then camped in Tellico, then up the Smokies, on to Ashville, then camped in Pisgah NF. It was a blast, and the rig did very well. I did not notice a specific drop in mileage from the tent, but could feel the weight of the bumper, tent, extra battery, and fuel cans. My next big thing will be stronger rear leafs.

http://img.photobucket.com/albums/v107/RaceBred/IMG_0390.jpg

http://img.photobucket.com/albums/v107/RaceBred/IMG_0400.jpg

http://img.photobucket.com/albums/v107/RaceBred/IMG_0442.jpg

http://img.photobucket.com/albums/v107/RaceBred/IMG_0474.jpg

http://img.photobucket.com/albums/v107/RaceBred/SDC12192.jpg
we had a battery powered lantern from hurricane stores; it worked good for the time being.

http://img.photobucket.com/albums/v107/RaceBred/SDC12193.jpg
really comfy inside. I picked up a teaton sports mammoth 0* bag; the good is being warm in 20 degree temps; the bad is that it is too big to be folded up within the tent. We resorted to folding half of it in in tent, and packing the other part in the stuff sack.

http://img.photobucket.com/albums/v107/RaceBred/SDC12437.jpg

http://img.photobucket.com/albums/v107/RaceBred/SDC12504.jpg

I will post some pictures of the dual battery setup as soon as I can.

-Eric

[Squall Line]

Here are the pictures from the work prior to the trip. I got the aux battery and charging system in, as well as installed an inverter for charging up the cameras and laptops.

http://img.photobucket.com/albums/v107/RaceBred/IMG_0268.jpg
basic layout
http://img.photobucket.com/albums/v107/RaceBred/IMG_0274.jpg
drilled holes for the rivnuts and through bolts
http://img.photobucket.com/albums/v107/RaceBred/IMG_0304.jpg
basic charging circuit
http://img.photobucket.com/albums/v107/RaceBred/IMG_0305.jpg
A closeup of the crimps. I used a vice and a $17 hammer type lug crimper. I am happy with the result.
http://img.photobucket.com/albums/v107/RaceBred/IMG_0321.jpg
clearance on the fridge
http://img.photobucket.com/albums/v107/RaceBred/IMG_0322.jpg
http://img.photobucket.com/albums/v107/RaceBred/IMG_0328.jpg
pretty much a mess. This was an all-nighter 2 days before the trip.
http://img.photobucket.com/albums/v107/RaceBred/IMG_0386.jpg
rails for the inverter

[Squall Line]

http://img.photobucket.com/albums/v107/RaceBred/IMG_0799.jpg
here is the finished product. I still need to make a cover for the back wall.
http://img.photobucket.com/albums/v107/RaceBred/IMG_0800.jpg
highlift installed with the tent rack
http://img.photobucket.com/albums/v107/RaceBred/IMG_0801.jpg
as with everything else on this truck- a close fit
http://img.photobucket.com/albums/v107/RaceBred/IMG_0803.jpg


Here is some more information regarding the dual batteries: I wanted to be able to put all accessories on one circuit, but not be tied to having the second battery in place at all times. This simple marine switch allows me to: Run the accessories off only the 2nd deepcycle, run the accessories off only the main, or combine them for emergency winching/ starting. The switch inline with the vsr allows safe removal of the second battery (no hot lead hanging in the toolbox). I have not done much research on how people are doing their batteries, but being able to run accessories off the main battery was a feature I decided to work in (haven't seen any specific examples of this same setup). My second battery is an exide orbital mounted in the tool box. I use this same battery for the trolling motor on my boat, and wanted the ability to remove it for around town driving...

Eric

[xterraoffroad]

Very nice install, this is great stuff!

I would love to have an aux battery for my Xterra, having little mechanical ability I'm thinking about a configured package like the National Luna Portable Power Pack.

[mcm4090]

http://img.photobucket.com/albums/v107/RaceBred/IMG_0799.jpg


What do you have the axle mounted in?

[Steel_City_X]

Okay,
I missed the source of the hinge assembly for you truck. Any link would be appreciated.

I've seen lots of spindles, but not liking the connection below the arm. You have support above and below the arm - taking both tension and compression forces. I've seen some gate hinges that are also very beefy.

I have an Xterra and want a rack off back for fuel, water, generator. The design of the hinge is very appealing for my purposes.

[Squall Line]

mcm4090: the axe is held by a quick fist on top (sierra expeditions has them), and the packaging that came with the axe at the bottom. This is in an existing hole, and I am not sure if it is permanent.

Steel City: There is no origin of the hinge other than a bearing supply store. It is simply two tapped-base pillow blocks. I have two 3/4 inch bearings with a 3/4" grade 8 bolt spanning them. I have not seen this design before, and was a product of chance that the idea worked out so well. It should be easy enough to piece together something of your own.

-Eric

[Something]

who makes your gas can holder?

I saw AT...who's that?

[bigdog]

who makes your gas can holder?

I saw AT...who's that?

AT = Adventure Trailers - Off Road Trailers & Overland Equipment (http://www.adventuretrailers.com/)

[Something]

AT = Adventure Trailers - Off Road Trailers & Overland Equipment (http://www.adventuretrailers.com/)

thank you sir

they're out of stock....bummer...

[Trogdor]

Your Fronty has to be one of the coolest I have seen in a long time! I am wanting to do the same to my truck which is a full size Dodge. Man your truck looks awesome! Keep up the good work.