[rockcod]

Quality work Kevin, now I am really bummed I sold the LWB.

Are the bed floor supports the same for a SWB?

[Awl_TEQ]

Don't know - never seen one. Probly not much different though. I'm gonna have to go to a gathering with a tape measure, calipers and a notepad .

[whitey45]

Kevin, I have mint bed sides,tailgate, but no floor or back panel. I had a flat bed with the sides removable. So now I am building a stock truck and would love to have a factory looking bed floor.Hopefully you will be doing the floor as well. I will definately be interested in the bed supports and back panel so put me down for a set of supports and the back panel. Again very nice work,this will make a lot of 45 lwb owners happy...Whitey

[Awl_TEQ]

When I get all the parts done to my satisfaction I will start a new thread, likely in the 45 classified section, with photo's of each and every piece in the bed as well as popular sub assemblies and a fully assembled bed. The prices (relax, I don't have them yet) will be with each photo and any options will be explained fully including the differences through the model years. I expect this to happen in the next three weeks to a month.

In the meantime, everyone please keep posting comments and observations. I particularly like the "great job" and "nice work" posts . Oh, and if you have info on manufacturing details specific to a certain year(s) Please post up in the "help me make" thread. Still looking for a pic of the front corner floor of an early model.

[71FJ40]

Kevin - for what its worth:
http://forum.ih8mud.com/fj45-classif...-long-box.html

Got more on the way from a friend...

[71FJ40]

http://forum.ih8mud.com/fj45-owners-...solutions.html

66-67 with riveted panels
http://forum.ih8mud.com/fj45-owners-...bed-floor.html

[HJ47]

OK Kevin,

'Great Job!' and 'Nice Work!' Now, don't let this slow you down on your FJ45 re-build...

It is amazing what a lot of skill AND really cool machines can make. How are you going to make the external arches for the wheel wells?

Cheers,

Josh

[Awl_TEQ]

Awesome links Jason, thanks. Got the picture I needed



Awwww Josh, careful my head is swelling .

[79fj40moneypit]

Awesome Work great job still wishin I had a 45 so I could buy parts

[Awl_TEQ]

Family obligations kept me away from the shop Friday and Saturday but today I was able to put in a full day.

Here the end and bottom flanges are formed


Ready to weld


Welding

[Awl_TEQ]

And welded - nice and flat

The details where the rib ends and the flange where the hip curves. This is pre-clean-up. It'll be purdy after I take the flapper disc to it.

The inside will be buffed down as well

[Awl_TEQ]

Bent up the cross members and the front corner parts on the 10' Amada (Got the replacement right 'Z' axis drive motor and encoder in on Monday )


Here are nearly three sets of cross members. Starting at right: Front wall top Z-channel, and then mounts 1 thru 5. These are slightly (0.014") thicker than the factory original. Original is 13 Ga, I am using 12 Ga (because we don't stock 13 Ga.) They are faithful reproductions of the (my) original bed. I did however add holes on the bottom flanges to locate the parts in a jig when spot welding the floor to them.


These are the front corner parts. The channel is where the front wall joins to the side. I call the channel the "front wall end channel". The angle under the channel is what I call the front corner post. The bed side panel wraps around this angle and is spot welded to it on two sides (not in this photo, this is just a dry fit).

[Awl_TEQ]

Here I am holding the front wall Z channel in approximate position. Note where the side panel rib ends - I think it stops there because the corner post is welded there - the same thing happens in the back where the rear corner post is welded to the side panel. Also, this side panel is for a local member who doesn't want the headache rack mounting holes, hence no holes.


Another view


Here you can see my technique for accurately assembling the three parts that meet in the corner. These are called "half-shears". It's a bump similar to the dimples in the side panels only it is much more defined and exactly 0.125" in diameter. What I do is punch a half-shear in one part and a 0.130" through hole in the mating part when the parts are on the turret punch.

[Awl_TEQ]

Got home and took my biker girl out to Elbow Falls on the Harley. Doesn't look like much but it's a good 25-30' drop.

[71FJ40]

You are a true craftsman!!

[Bear]

And it looks like you're somebody's favorite Daddy.
Good work, Dad, on both counts.

[a.greenspan]

....think Toyota becomes a problem when you built better cars than they do
great job Awl_TEQ
Cheers
Peter

[fjwagon]

Whitey,

Can you please post the sides of your bed? Does it have the Dimples near the hooks like Kevin's Bed?

Originally Posted by whitey45

Kevin, I have mint bed sides,tailgate, but no floor or back panel. I had a flat bed with the sides removable. So now I am building a stock truck and would love to have a factory looking bed floor.Hopefully you will be doing the floor as well. I will definately be interested in the bed supports and back panel so put me down for a set of supports and the back panel. Again very nice work,this will make a lot of 45 lwb owners happy...Whitey

[D'Animal]

I'm trying to imagine how Toyoda would have bent the sheet metal in the early 60's to make these beds.

Originally Posted by a.greenspan

....think Toyota becomes a problem when you built better cars than they do
great job Awl_TEQ
Cheers
Peter

I doubt they had the computer controlled machine that Awl_Teq has.


Did someone mention that you were going to start making roofs once you get caught up with the LWB and the SWB bed orders?

[Awl_TEQ]

Originally Posted by D'Animal

I'm trying to imagine how Toyoda would have bent the sheet metal in the early 60's to make these beds.




I doubt they had the computer controlled machine that Awl_Teq has.


Did someone mention that you were going to start making roofs once you get caught up with the LWB and the SWB bed orders?

They made them with brute force and a one hit tool that took a flat blank and stamped out a finished part.


No comment.

[HJ47]

OK Kevin, you make the bodies for FJ45s, and I'll ship over all the HJ47 frames I can find. I reckon there would be a market for them if the cost could be less-than the Icon. Just think of the potential: a ready-made shell made entirely out of steel, with a Toyota title, then the customer can put any drive-train and suspension in it they want. Let's see how long it takes to really piss Toyota off.

Josh

[Awl_TEQ]

They started it by discontinuing the 40/70 series in north america!! And then making the LC a $100,000.00 unit . For a hundred grand I'll put wheels and a snorkel on grandma before buying one (lotto notwithstanding ).


rant over

[HJ47]

I couldn't agree with you more. Besides, your craftsmanship leaves the Toyoda boys for dead.

Josh

[Awl_TEQ]

AHHHHH! MY HEAD IS SWELLING AHHHH!









I'm good at copying at least. Plagiarism is the sincerest form of flattery

[HJ47]

I agree- that's how the Japs came up with the F engine and Toyoda Jeep. They took an existing design and 'copied' it whilst making it better. It seems to me that is exactly what you are doing; turnabout certainly is fairplay. I just wish I could fit in a pickup so I could buy one of your beds

Josh

[Awl_TEQ]

Made three main floor sections at work today (well, after work really).

Loaded the tools, programmed the press break and practiced on a 12" length of the floor profile. I originally planned to only verify the programming but then once I had everything set up it made ore sense just to do it. The 12" sample came out the right width so I got a buddy to help me bend up three full length floors. Takes about 25 mins each with 60 bends each plus the rib ends.

[Awl_TEQ]

Took the sample home and set it on my messy bed.

Here you can see the left and right ends close up. Mine is about 1/8" narrow but with the overlap of the spot weld joint it will be fine. The ribs are correct center to center, I just need another 1/16" of material on each end of the profile.

[Awl_TEQ]

More...

[krzyabncanuck]

All this and rebuilding 2 8274's.

You have amazing craftmanship there.

[Awl_TEQ]

I don't show you guys the error part of the trial and error - makes me look good




A little more today... these are the access covers for the front corners of the floor.