2001 Double Cab Build

[zmotojason]

Hi all. I've been lurking on the forum for months, gathering ideas and inspiration from all of your builds. It is now time to start documenting my build.

My truck had been stock until December 2011, when my old tires wore out and were replaced by 265/75 BFG All Terrains. I did some milde wheeling and the new tires rubbed a bit, so an OME lift was installed between Christmas and New Years. With added clearance, I hit some nastier trails and realized that some body protection was needed. So begins the first of my build pics.

I built a set of sliders from 2" x 1/4 wall receiver stock and 1.5 x .120 round tubing. It took about two weeks from start to install.

The square stock was cut to length, mitered and sealed shut.

20120121_162721.jpg

Mounting brackets were made from receiver stock and 4" angle cut to size.

20120123_184533.jpg

The brackets were welded to the main slider body and tubing was bent up to exetend the protection.

20120205_121418.jpg

Additional bracing was cut and notched and everything was welded to the main slider body.

20120206_210922.jpg

A pair of completed, unpainted sliders.

20120207_212840.jpg

The sliders were painted with POR-15 paint and covered with their Chasis Coat to keep the paint from oxidizing. This paint is pretty cool. It goes on with a brush and self-levels. It dries really hard and seems to be incredibly durable. Much cheaper than powder coating and it can be touched up when needed. I don't have any pics of welding the sliders to the frame, but here is the finished product.

There is about 3/8" to 1/2" gap between the mounts and the body seam. The round tubing is about even with the outside edge of the tires.

20120226_111752.jpg20120226_111806.jpg

[zmotojason]

The next project was creating a mounting system for a Hi-Lift, shovel and axe. I found a mount I liked on one of the forums and ran with it. If this was your design, thank you!

I don't have any pics of the build, but here are some of the finished product. The shovel and axe are held in place with Quick Fists and the jack is mounted with studs and wing nuts. The rack mounts between the stock tie downs.

20120222_210214.jpg20120226_112138.jpg

[Owyhee H]

Looking Good! Those sliders are plenty stout.

[zmotojason]

The next step in the build was making gussets to strengthen the rear frame. I cut a template out of cardboard and use the plasma cutter to cut the gussets from 3/16" plate.

20120521_204055.jpg

A pair of frame gussets.

20120521_210511.jpg

Holes were cut for rosette welds and the frame was prepped for welding.

20120526_110225.jpg

The gussets were welded around the entire perimiter and in the rosette holes. After cooling and some cleanup with the the wire brush, they were rattle canned with black Rustoleum automotive paint. It seems to be more stable on the road, but I may just be imagining things.

20120526_114253.jpg

[enzo]

Looks like your off to a good start. Those sliders are awesome.

[YotaPilot]

Nice welding skills. I wish was able to fabricate my own stuff.

[samguert]

Nice thread! Keep it going!

[washington taco]

Since installing my frame doublers on certain freeways (severely worn) the rear almost feels like it hops. I plan on new rear springs this fall and hope this resolves the issue.

[zmotojason]

Started work on a swing-out spare tire carrier with hardware purchased from AtoZFabrication.com. I toyed with the idea of building a new bumper but in the end decided to modify the bumper I already have.

I decided to notch the wrap-around tube protectors to carry the spindle. Once in place, the spindle will be plated top and bottom and tied into the rectangular tube.

20120611_182115.jpg


Out came the plasma cutter.

20120611_185616.jpg

The result of much cutting and fitting.

20120611_190103.jpg 20120611_190120.jpg


I had some leftover 2" square receiver stock that was cut to length and notched for the bearing carrier and tacked it into place.

20120625_174451.jpg

The tire carrier was set on the bumper, everything was squared up and the spindle was tacked into place.

20120625_175716.jpg

Now the bearing carrier could be finish-welded.

20120625_182149.jpg

Tonight the plan is to finish-weld the spindle to the bumper and add begin cutting/ fitting the plates to the rectangular tubing.

[zmotojason]

Finally made a little more progress on the bumper. Welded in the spindle.

20120702_200133.jpg

Also got the spindle partially plated in. I layed down a fat bead of weld and then smoothed it out with a flap wheel. Once painted, the bumper should look like it always had the swing out tire carrier.

20120702_215156.jpg