[Awl_TEQ]

A couple shots of the cross-members. The rear valence and the two hat channels over the arch in the frame are not shown - because I haven't made them yet

[cruiseroutfit]

Unbelievable, excellent work

BTW, what is the current lead time looking like for a fully assembled tailgate (minus hooks, letters and latches of course)

[a.greenspan]

Originally Posted by Awl_TEQ

Attachment 323939

....
....Kevin you need new tyres

[Awl_TEQ]

Originally Posted by cruiseroutfit

Unbelievable, excellent work

BTW, what is the current lead time looking like for a fully assembled tailgate (minus hooks, letters and latches of course)

I should be able to do the hooks now also - three weeks should be enough time with my current workload. Three or four hinge?

Originally Posted by a.greenspan

....
....Kevin you need new tyres

There's lots of life left in those re-treads...

[My wife said no FJ!]

Man that is some nice work...looking forward to you tackling your brother's simpler 40

[Awl_TEQ]

The rearmost cross member (not the rear valence with the tail lights) has a different mounting bracket. This one is made of 1/4" plate and welded to the crossmember facing forward. In this pic you are looking rearward at the right hand side mount and can partially see the tail light cutout at bottom right.

Today I fabbed up an exact copy of the bracket in all dimensions. Made 14 of them, though I messed up one of the holes and got 13 good ones.

Here it is clamped in position on my frame. My frame has been altered but the hole in it is in the stock location.

[Awl_TEQ]

I measured up my original then programed and punched out a couple of four hinge rear valences.

I formed them up and added captured M6 nuts for the hinges and the rear corner post (the thing your tailgate chain attaches to). FYI the large pan behind the valences is JIG to hold the floor cross members and the rear valences in position when I spot weld the center floor section on. That will assure the proper location of the mounts when the bed is eventually set on a frame.

Here is a close up of the tail light cutouts. The factory original has the lights recessed in an embossed depression but I can't do that so these are just flat. Notice the hole for the reflector just above the light cutout.

[Awl_TEQ]

Here is the original embossed/ recessed tail light I mentioned. I just don't have a tool to press that in so mine will be flat at least for now...

Here I test fit my tail light. The holes for the bolts to mount it are off slightly but this is a prototype and any future ones will line up. Incidentally, I will be making three hinge versions as well as valences to suit the other tail light designs. Or custom for that matter .

With the lens set in place...

[Awl_TEQ]

So mine will be a surface mount affair rather than recessed a half inch. In this pic the lens is not tightened down, or the light for that matter.

Here I set the rear valence in approximate position so I could stand back and admire it. Man, I can't wait till I can assemble the whole thing.

Note the ends of the valence are offset inward. That is to let the rear post overlap and still be flush. Also you can just make out the captured nuts in the hinge holes and end holes.

[Awl_TEQ]

I also laid out and punched/ formed up the bed hooks. I wasn't sure I could do these but I am pleasantly surprised at the outcome. They still need the front seam welded and a back put on but you can recognize the shape easily. I'm thinking I will zinc plate these because I, or you, will never get them coated inside. I will leave a small hole like the original in the bottom for moisture drainage.

[Awl_TEQ]

It was such a pain to setup the bending I decided to make a bunch while I was at it. I think I've got about 50. At 13 per truck thats only four trucks.

In this shot it mine looks bigger but its just closer

Mine is a little longer but for this run I'll fix that by just grinding it shorter when finishing the welds.

[Awl_TEQ]

One last shot of the hook and a couple for reference tomorrow. I hope to put together the floor, cross members, rear valence, front and rear corner floor sections and maybe some parts of the front wall of the bed.

Center floor section to out side of rear valence average 1.125"

Front wall and cross member to front corner post 3/4" (other side is 7/8" )

[a.greenspan]

Originally Posted by Awl_TEQ

Attachment 324469

Kevin it`s always nice to see you working
have a question:
How made Toyota these hooks (they are more round on the edges) are they stamped ?
Lurking your new made hinges, maybe I need two
Cheers
Peter

[Awl_TEQ]

Peter,

I think they were stamped out in a two stage die. The material wraps around and closes the back of the originals leaving an unwelded seam up the back. Mine will be more rounded after welding the seams up the front and shaping the tip. There will be some tweaking of the blank layout for future runs to perfect the shape but these will look fine when finished.

I might make hinges but I haven't really thought about it. There are some hinges being sold in the classified for the early trucks that look very well made.

Kevin

[71FJ40]

Truly impressed with the hooks!
It is so interesting seeing the "flat" plate from which the hooks were born

A+ as always!

(Wish you were closer so I could come over and help/learn/watch )

[a.greenspan]

Originally Posted by Awl_TEQ

....There are some hinges being sold in the classified for the early trucks that look very well made.
Kevin

I know them, well made sure ..


..but don`t compare with my old hinges.
Cheers
Peter

[Awl_TEQ]

I had a chance to practice my TIG welding today. I've been working toward assembling a floor section so needed to finish some welding.

It doesn't have to be perfect...

because I'm gonna make it disappear anyway.

[Awl_TEQ]

The full picture

Added stainless steel captured M8 nuts in the cross members for the parts of the floor that are bolted down.

Welded the mounting brackets on. I was just going to spot weld them on but the guy who knows the finer points of setting up the spot welder wasn't in so I TIG welded them.

[Awl_TEQ]

More welding - this is the rear most mount

the rear valence

I set the cross members on my jig being careful to get them all facing the right way. The three rear cross members are shimmed up 3/8" as they are that much shorter.

[Awl_TEQ]

I set the floor on and kind of located it in position - just a matter of centering it and spacing it front to back.



Now I get to see if my corner floor sections fit. They do, at least with only minor tweaks. They aren't finished yet but they fit.

[Awl_TEQ]

Random shots

[Awl_TEQ]

More random shots

[Awl_TEQ]

So just as I was on a roll...






It was time to go home



Worse yet, I can't do any more until next Wednesday. The wife is flying to Vegas and I get to spoil the kids.

So I set everything aside and marked it do not touch

[oldfj40]

Looks excellent Kevin.

[cruiseroutfit]

Originally Posted by Awl_TEQ

I should be able to do the hooks now also - three weeks should be enough time with my current workload. Three or four hinge?

3 hinge and I would need to figure out a way to get it to Salt Lake City

[Awl_TEQ]

I would need some measurements for the three hinges locations. Should be safe to assume the middle one is in the middle but what's the spacing for the outer ones? I would need the distance between the two holes on a single hinge and then the center to center distance from hinge to hinge. Preferably using calipers for the individual hinge hole spacing and then as accurate as possible hinge to hinge (like 1/32" at least.

Other option is to drill the holes yourself and tack weld some nuts inside the channel. But why do that if I can do t for you included in the price?

[Leaping Deer]

Wow. Amazing work!!!! Keep it up

[a.greenspan]

Originally Posted by Awl_TEQ

..next Wednesday. The wife is flying to Vegas and I get to spoil the kids.

..it`s Wednesday, local time Berlin:timeanddate.com - Berlin - Berlin - Germany time
wife must be back, the kids are ok Kevin ?

[Awl_TEQ]

Originally Posted by a.greenspan

..it`s Wednesday, local time Berlin:timeanddate.com - Berlin - Berlin - Germany time
wife must be back, the kids are ok Kevin ?

She's back tonight. I gotta get the kids and head to the airport after work.

I hope she's coming back - I got a text message a couple of days ago "ran out of money, send more!!"

I'm going to get back at it on Friday afternoon. We finish work at 11:00am on Fridays so I'll have the afternoon and Saturday to get it together. My welder, Shawn, is coming in Saturday to finish the bed sides and I will weld the other stuff myself.

Thursday I have to clear coat my buddies motorcycle and then that'll be out of the way.

[D'Animal]

Looking forward to the pics.