Build Our PanAm rig build thread

[FlyAddiction]

I have acquired all the materials to build a skid that will be centered and leveled under the truck. I will then build a frame that will support the front half and another that will support the rear. I will then use a laser to mark cut the body, cut it and then cut the frame. Once cut, I will slide the rear half on the skid and it should keep the whole thing fairly straight and level to weld the extension in.

 

[FlyAddiction]

Everything is now removed from the rear half of the body including the gas tank and drive shaft. I fabbed up the rail jig and will now build the frames that support the front and rear half independently.

 

[FlyAddiction]

The jig is done and the truck is fully secured and level. Ill probably be able to cut the rear tomorrow! Pretty nerve racking, there is no going back now!

 

[RC51]

What a journey…

 

[FlyAddiction]

Here we go. A week of prep and 20 min to cut!
The lazer was mandatory on that job. I also took out the sun roof in anticipation for the roof cut.

 

[thelal]

Here we go. A week of prep and 20 min to cut!
The lazer was mandatory on that job. I also took out the sun roof in anticipation for the roof cut.

View attachment 3837688

View attachment 3837689

View attachment 3837690

wow

 

[FlyAddiction]

Boy its a lot of work! Getting decent progress but still lots to do. The frame extension along with the LCA brackets and new body mounts are now in. The rear rool cage/headache rack is built as well as the new roof section.

 

[FlyAddiction]

Frame extension kit from mckinnon cruisers in Australia. Resonably priced and saved a bunch of work! Well worth it.

 

[FlyAddiction]

In order to weld the top of the fish plate inder the cab, I had to disconnect all but the front body mounts, jack the rear of the cab by 10" and use my stubby tig torch. It was a verry tough weld to lay. I am glad that I spent the time and build the skid to support both pieces while de frame was cut. It helped tremendously with keeping everything allined. I also used a couple lenghts of 4" angle iron clamped to both ends of the frame rails to fine tune alignment and spacing while burning in the extension pieces.
Next, paint hte frame, make the rear and roof panels to close the cab, paint all the fabricated items with 2k epoxy primer and raptor liner. Reinstall the gas tank, make new brake lines, new drive shaft ........ ...... ........

 

[FlyAddiction]

Random pictures of the build

 

[FlyAddiction]

Cab rear pannel design

 

[FlyAddiction]

Brake lines have been extended and the gas tank is back in. I Also made 6 aluminum brackets that will hold down the roof section in addition to being glued in

 

[FlyAddiction]

Blead the brakes , changed the rear calipers, slaped a seat in it. Added some temporary brackets as a level refference point for the flat deck and took it off the jig. Quite a milestone to have a rolling chassis. It will make working in the shop much easier with the ability to wheel it out.
I also made the roof pannel with stifners and extended the exhaust.

 

[FlyAddiction]

E brake cable completed using a generic kit from amazon and connecting it to the stock one. Not the prettiest but it works great.

 

[clrussell]

Well this escalated quickly

 

[FlyAddiction]

Cut the rear pannel, i will put an rv sliding window on it. Built the rear body mount directly on the bottom of the rear frame. Started building the flat deck with 2in x 1/8" 6061 tubing. Turned half the garage into a paint booth to prime and paint all the parts to close the cab. I used black Raptor liner thined 20% and used a hvlp setup. The finish turned out great. Very light texture as oposed to using the gun that comes in the kit.

 

[FlyAddiction]

Chipped away all the old sound deadening as it was impregnated with oil and permeating thru the carpet. Installed new stuff. Took forever! Spliced the wiring into a junction box where it will split to the diferent lights and trailer wiring from there.

 

[FlyAddiction]

I guess i suck at updating this build on mud... lots of work since my last post and lots to come. I decided that the camper will be mounted permanently to the truck. This will make the build around 200lbs lighter than othewise. Photo dump of the rear flatish deck including the torsion free single pivot i designed.

 

[FlyAddiction]

 

[FlyAddiction]

Filling in the old wheel well, this will be a storage box accessed from the inside only. It will be easier to keep dry and secured.