M101 tailgate & homemade fold out tent...

Zekester · 05-11-08, 09:03 PM

So I zip cut the tailgate out last night, tonite started the tailgate, Tuesday on to the fold out tent rack, I'm going to post all the pics as I go.... First pic is is the tailgate I cut out, ...2nd The Finnish Flash boxing in the tailgate with 1X1, 3rd the trailer...wrong order I know...

Zekester · 05-11-08, 09:20 PM

4th pic, boxing in tailgate with 1 x 1 to match the other two pieces of 1 x 1 already on it...5th pic the detail of the 1 X 1 around the heavy plate in the lower corners of the tailgate,
6th pic, the trailer, 1/2" angle set into the bottom, after we cut back the folded steel at that point, 1/2" angle boxing in the hole...

Zekester · 05-11-08, 09:24 PM

next pic, the detail of the angle set into the floor..it's flush with the floor, and gives me the spot for the hinges, tying them to the box...the last pic shows it from the inside, the angle being tacked up the sides of the hole...

We did the gate fitted in and the hinges tacked on, but no batteries,..Tuesdau night will update, and begin the fold out tent part....

REZARF · 05-11-08, 09:32 PM

Lookin' good man! Keep it up!

KingBeeIII · 05-11-08, 10:39 PM

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Keep the pics coming.

sseaman · 05-12-08, 07:17 AM

good progress, cant wait to see the tent ideas

Zekester · 05-12-08, 08:06 AM

For the tent rack, I'm basically making a 7 X 4 rack out of 1 X 1, that will sit on the trailer. Attached on one side by a hinge is a 5" X 7' panel, with another hinge attached to a 41-5/8 X 7' panel. all panels are covered with 5/8" ply. So it kind of unfolds twice, this gives me 5 inches to leave the tent, bedding etc, in the rack when folded...I've cut and routered the ply, and cut my 1 x 1 to length, will start welding tomorrow night, pics to follow..

pint · 05-12-08, 08:43 AM

Great work...keep it up!

Zekester · 05-14-08, 08:43 PM

Slow night, two pics, tigged on the hinges, welded up the open 1x1 ends, cleaned up the welds, drilled and tapped holres for the latches...I'm putting some sikaflex on the joints to match the sealer on the rest of the trailer, maybe paint tomorrow night, I'm planning on painting it to match the trailer, but for now, just spray bomb the mods with olive drab...

Zekester · 05-15-08, 10:11 PM

Painted the tailgate, cleaned up welds and sealed up the trailer, the bar across the top is the first bar of the fold out tent, just for mock up...

Zekester · 05-16-08, 10:50 PM

Tailgate paintes and installed, latches in place, the reflectors went back in the stock holes...I hung it open just to show it, I'll be installing two aircraft cables to support it...

On to the tent rack....on Tuesday : ) Long weekend now : )

REZARF · 05-17-08, 05:10 PM

One of the cleanest mods for a tailgate I have seen, great job dude.

Looking forward to the rest of it.

Drew

KingBeeIII · 05-17-08, 06:30 PM

Impressive, most impressive.

airlaird · 05-19-08, 11:34 AM

How did you make your straight cuts...simply by eyeballing it..or did you have some straight edge steel as a guide to keep the cut straight with the zip wheel?

airlaird

Zekester · 05-19-08, 11:46 AM

For the vertical cuts, I clamped angle to the trailer on the inside, then layed in it and zipped it, it really sucked, you are in a box with the sparks bouncing all around...then I went outside and finished the cuts through the 1 x 1. For the long horizontal, I cut just under the plate at the corners, from the outside, then connected the two cuts by eye. This was tricky as I didn't realize that there is a double folded layer inside the trailer right here, I cut it in different places, so to make it even i dressed it back 1/2 inch, then welded in the 1/2" angle so it formed a new lip on the trailer...

Mud Shark Rosey · 05-23-08, 04:54 PM

Nice work Mike. You going to be bringing it up to Ardbeg when we go?
Dave

Zekester · 05-25-08, 08:23 PM

just let me know

Zekester · 07-16-08, 09:30 PM

Ok, starting the folding tent rack...basically I will have a 4' X 7' rack mounted to the trailer, attached on one side by a hinge is a 5" X 7' rack, attached to that rack also by a hinge is a 3' 5" x 7' rack. The hinges are 1" pipe with 1/2 bolts as the pivot. when unfolded it gives me an 8' X 7' platform. when folded, it is bi-folded, so it gives me a 5" space to leave the tent and bedding inside. all the racks are covered with 1/2 plywood, sealed and painted.

Attached pics, -one sheet of ply with the beginning of a rack,
- the three racks,
- three racks again

Next few nights I'll weld on the hinges and suport brackets...

REZARF · 07-16-08, 09:56 PM

This just got crazy interesting!

Keep it up, can't wait to see the final product!

Zekester · 07-16-08, 10:45 PM

I certainly am getting a lot of strange looks when people drive by in the parking lot at my firned's shop...with us holding and clamping all the square tube...told one guy it was cage for mountain lions : )

and I made it inside without cracking a smile...

Zekester · 07-18-08, 09:06 PM

I've got the rack welded together and on the trailer, you can see how it extands past the front of the trailer giving 7 feet, and once unfolded giving 8 feet, for a 7 x 8 platform...pics below show the double hinge made out of 1/2" bolts, the locking mechanism when it's folded (without locking pin). The two pieces that are angled laying into the trailer are the outrigers for the unfolded rack, once the plywood is on they will fold into that in be held in place, the racks have been drilled and tapped so the ply will be held on with flush bolts, with no nuts sticking out.

now just have to finish the screw type outrigger feet, and the C-channel that goes across the three racks when unfolded which wil keep the 3 pieces aligned....

Zekester · 07-18-08, 09:07 PM

two more pics mentioned in previous post...

REZARF · 07-19-08, 10:40 AM

Maybe I am missing something here (not uncommon)

How will your hinge become rigid? It looks like the hinge will span the gap instead of the tubes coming together and "bracing" on another, is that right? Sorry I can't really tell from the pics. I love the idea keep it coming!

Drew

Zekester · 07-19-08, 11:47 AM

I'm not sure I understand the question...but I'll try to answer what I think you are asking...

when its unfolded you'll have 3 pieces with two hinges between them. Two 20" of C channel have been made up to horizontally slide onto the three pieces, bridging them from each side. The C channel has holes for two pins to drop in vertically, locking it in place. Now the two main sections will be locked together with the small floating section locked between...the platform will then be supported by two drop down outriggers to keep the locked platform from tipping the trailer...

I'll try to take picks tonite of it folded out before I dismantle it for paint....

REZARF · 07-19-08, 01:10 PM

Makes perfect sense now. Looking great, keep it up.

boots · 07-20-08, 02:09 PM

Quote:

Originally Posted by Mszekely

Tailgate paintes and installed, latches in place, the reflectors went back in the stock holes...I hung it open just to show it, I'll be installing two aircraft cables to support it...

On to the tent rack....on Tuesday : ) Long weekend now : )

This has got to be one of the CLEANEST tailgate installs I have seen. Very Very good work. Now, when can I bring mying over for you to do ?

05-11-08, 09:03 PM	#1
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	M101 tailgate & homemade fold out tent... So I zip cut the tailgate out last night, tonite started the tailgate, Tuesday on to the fold out tent rack, I'm going to post all the pics as I go.... First pic is is the tailgate I cut out, ...2nd The Finnish Flash boxing in the tailgate with 1X1, 3rd the trailer...wrong order I know... Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica Last edited by Zekester; 05-11-08 at 09:05 PM. Reason: correct details

05-11-08, 09:20 PM	#2
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	next 4th pic, boxing in tailgate with 1 x 1 to match the other two pieces of 1 x 1 already on it...5th pic the detail of the 1 X 1 around the heavy plate in the lower corners of the tailgate, 6th pic, the trailer, 1/2" angle set into the bottom, after we cut back the folded steel at that point, 1/2" angle boxing in the hole... Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

05-11-08, 09:24 PM	#3
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	next next pic, the detail of the angle set into the floor..it's flush with the floor, and gives me the spot for the hinges, tying them to the box...the last pic shows it from the inside, the angle being tacked up the sides of the hole... We did the gate fitted in and the hinges tacked on, but no batteries,..Tuesdau night will update, and begin the fold out tent part.... Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

05-11-08, 09:32 PM	#4
REZARF IH8MUD Lifer Join Date: Sep 2003 Location: Louisville, CO TLCA# 13041 Posts: 2,839	Lookin' good man! Keep it up! __________________ Drew F. Rising Sun 4x4 Club 76 FJ40, 85 fj60 Engine and Ignition, 35" MTR's, Warn 8074, 4" of lift TPI, snorkeled, racked, Mini-truck P/S... and sometimes running. Friends don't let friends drive Thornbirds... My camping trailer build up thread.

05-11-08, 10:39 PM	#5
KingBeeIII Scorpions fear me. Join Date: Sep 2006 Location: Paper St. Posts: 543	Thread tools: click Subscribe to this thread: click Keep the pics coming. __________________ "On a long enough timeline, the survival rate for everyone drops to zero"

05-12-08, 07:17 AM	#6
sseaman IH8MUD Lifer Join Date: Sep 2006 Location: Nashville, TN Posts: 1,355	good progress, cant wait to see the tent ideas __________________ 91 FJ80 318k, spare tire mod, custom roof rack----SOLD 98 4runner 136k 98 Avalon 138k

05-12-08, 08:06 AM	#7
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	For the tent rack, I'm basically making a 7 X 4 rack out of 1 X 1, that will sit on the trailer. Attached on one side by a hinge is a 5" X 7' panel, with another hinge attached to a 41-5/8 X 7' panel. all panels are covered with 5/8" ply. So it kind of unfolds twice, this gives me 5 inches to leave the tent, bedding etc, in the rack when folded...I've cut and routered the ply, and cut my 1 x 1 to length, will start welding tomorrow night, pics to follow.. __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

05-12-08, 08:43 AM	#8
pint IH8MUD Lifer Join Date: Jul 2005 Location: Parker, CO TLCA# 17493 Posts: 1,093	Great work...keep it up! __________________ 2000 UZJ100, OME 865, OME T-bars, Slee Diff Drop, Slee SliderSteps, TJM T3, PowerStop Cross Drilled & Slotted Rotors, 295 Terra Grapplers M101 Trailer - Sold 1993 Bontrager Race Lite MTB

05-14-08, 08:43 PM	#9
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	Slow night, two pics, tigged on the hinges, welded up the open 1x1 ends, cleaned up the welds, drilled and tapped holres for the latches...I'm putting some sikaflex on the joints to match the sealer on the rest of the trailer, maybe paint tomorrow night, I'm planning on painting it to match the trailer, but for now, just spray bomb the mods with olive drab... Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

05-15-08, 10:11 PM	#10
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	Painted the tailgate, cleaned up welds and sealed up the trailer, the bar across the top is the first bar of the fold out tent, just for mock up... Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

05-16-08, 10:50 PM	#11
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	Tailgate paintes and installed, latches in place, the reflectors went back in the stock holes...I hung it open just to show it, I'll be installing two aircraft cables to support it... On to the tent rack....on Tuesday : ) Long weekend now : ) Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

05-17-08, 05:10 PM	#12
REZARF IH8MUD Lifer Join Date: Sep 2003 Location: Louisville, CO TLCA# 13041 Posts: 2,839	One of the cleanest mods for a tailgate I have seen, great job dude. Looking forward to the rest of it. Drew __________________ Drew F. Rising Sun 4x4 Club 76 FJ40, 85 fj60 Engine and Ignition, 35" MTR's, Warn 8074, 4" of lift TPI, snorkeled, racked, Mini-truck P/S... and sometimes running. Friends don't let friends drive Thornbirds... My camping trailer build up thread.

05-17-08, 06:30 PM	#13
KingBeeIII Scorpions fear me. Join Date: Sep 2006 Location: Paper St. Posts: 543	Impressive, most impressive. __________________ "On a long enough timeline, the survival rate for everyone drops to zero"

05-19-08, 11:34 AM	#14
airlaird IH8MUD Lifer Join Date: Jan 2005 Location: Dallas, Texas Posts: 1,127	How did you make your straight cuts...simply by eyeballing it..or did you have some straight edge steel as a guide to keep the cut straight with the zip wheel? airlaird

05-19-08, 11:46 AM	#15
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	For the vertical cuts, I clamped angle to the trailer on the inside, then layed in it and zipped it, it really sucked, you are in a box with the sparks bouncing all around...then I went outside and finished the cuts through the 1 x 1. For the long horizontal, I cut just under the plate at the corners, from the outside, then connected the two cuts by eye. This was tricky as I didn't realize that there is a double folded layer inside the trailer right here, I cut it in different places, so to make it even i dressed it back 1/2 inch, then welded in the 1/2" angle so it formed a new lip on the trailer... __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

05-23-08, 04:54 PM	#16
Mud Shark Rosey IH8MUD Rookie Join Date: Jan 2005 Location: Ont. Canada Posts: 52	Nice work Mike. You going to be bringing it up to Ardbeg when we go? Dave __________________ V.P Upper Canada Cruisers TLCA # 12778 1977 FJ40 1989 FJ62

05-25-08, 08:23 PM	#17
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	just let me know __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

07-16-08, 09:30 PM	#18
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	Ok, starting the folding tent rack...basically I will have a 4' X 7' rack mounted to the trailer, attached on one side by a hinge is a 5" X 7' rack, attached to that rack also by a hinge is a 3' 5" x 7' rack. The hinges are 1" pipe with 1/2 bolts as the pivot. when unfolded it gives me an 8' X 7' platform. when folded, it is bi-folded, so it gives me a 5" space to leave the tent and bedding inside. all the racks are covered with 1/2 plywood, sealed and painted. Attached pics, -one sheet of ply with the beginning of a rack, - the three racks, - three racks again Next few nights I'll weld on the hinges and suport brackets... Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

07-16-08, 09:56 PM	#19
REZARF IH8MUD Lifer Join Date: Sep 2003 Location: Louisville, CO TLCA# 13041 Posts: 2,839	This just got crazy interesting! Keep it up, can't wait to see the final product! __________________ Drew F. Rising Sun 4x4 Club 76 FJ40, 85 fj60 Engine and Ignition, 35" MTR's, Warn 8074, 4" of lift TPI, snorkeled, racked, Mini-truck P/S... and sometimes running. Friends don't let friends drive Thornbirds... My camping trailer build up thread.

07-16-08, 10:45 PM	#20
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	I certainly am getting a lot of strange looks when people drive by in the parking lot at my firned's shop...with us holding and clamping all the square tube...told one guy it was cage for mountain lions : ) and I made it inside without cracking a smile... __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

07-18-08, 09:06 PM	#21
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	I've got the rack welded together and on the trailer, you can see how it extands past the front of the trailer giving 7 feet, and once unfolded giving 8 feet, for a 7 x 8 platform...pics below show the double hinge made out of 1/2" bolts, the locking mechanism when it's folded (without locking pin). The two pieces that are angled laying into the trailer are the outrigers for the unfolded rack, once the plywood is on they will fold into that in be held in place, the racks have been drilled and tapped so the ply will be held on with flush bolts, with no nuts sticking out. now just have to finish the screw type outrigger feet, and the C-channel that goes across the three racks when unfolded which wil keep the 3 pieces aligned.... Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

07-18-08, 09:07 PM	#22
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	two more pics mentioned in previous post... Attached Images __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

07-19-08, 10:40 AM	#23
REZARF IH8MUD Lifer Join Date: Sep 2003 Location: Louisville, CO TLCA# 13041 Posts: 2,839	Maybe I am missing something here (not uncommon) How will your hinge become rigid? It looks like the hinge will span the gap instead of the tubes coming together and "bracing" on another, is that right? Sorry I can't really tell from the pics. I love the idea keep it coming! Drew __________________ Drew F. Rising Sun 4x4 Club 76 FJ40, 85 fj60 Engine and Ignition, 35" MTR's, Warn 8074, 4" of lift TPI, snorkeled, racked, Mini-truck P/S... and sometimes running. Friends don't let friends drive Thornbirds... My camping trailer build up thread.

07-19-08, 11:47 AM	#24
Zekester IH8MUD Addict Join Date: Nov 2006 Posts: 516	I'm not sure I understand the question...but I'll try to answer what I think you are asking... when its unfolded you'll have 3 pieces with two hinges between them. Two 20" of C channel have been made up to horizontally slide onto the three pieces, bridging them from each side. The C channel has holes for two pins to drop in vertically, locking it in place. Now the two main sections will be locked together with the small floating section locked between...the platform will then be supported by two drop down outriggers to keep the locked platform from tipping the trailer... I'll try to take picks tonite of it folded out before I dismantle it for paint.... __________________ Zekester SW Ontario, Canada 12/79 BJ40, 3B, Gozzard F/G body, Herculinered, 3" lift, SS snorkle M101 Expedition Trailer I/P 1997 BMW 328is 1957 Porsche 356 replica

07-19-08, 01:10 PM	#25
REZARF IH8MUD Lifer Join Date: Sep 2003 Location: Louisville, CO TLCA# 13041 Posts: 2,839	Makes perfect sense now. Looking great, keep it up. __________________ Drew F. Rising Sun 4x4 Club 76 FJ40, 85 fj60 Engine and Ignition, 35" MTR's, Warn 8074, 4" of lift TPI, snorkeled, racked, Mini-truck P/S... and sometimes running. Friends don't let friends drive Thornbirds... My camping trailer build up thread.