Safari Pacific MX2 Buildip
#301
04-19-2009
#303
05-26-2009
Join Date: Jul 2008
Location: Temecula, CA
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Thanks all! Tons of updates coming up. Cab finishing, bed reinforcement, camper installation & demonstration, rear bumper build.
During the time bodywork was being done there were a few days I worked on the wheel well portion of the cab. To keep the tires from ever
rubbing against the cab I notched the edges with a plasma cutter.
After the rough cut I cleaned up the edges, then proceeded to create a paper template for a new edge.
Then I transfer the template onto a piece of 16 gauge sheet steel.
With a sheet metal break I bend the strait edges accordingly. Then I use a body hammer to beat each little tab into place then tack weld it.
As you can see by the number of small tabs this took a long time. The back of the cab has ridges making it very difficult.
Once fully in place I welded up every inch and repeated on the driver side.
When finished I sand blasted and smoothed the edges with seem sealer.
Once the truck was back together I took it out for a test run. Part of the test was to see if the tires would rub or even come close.
With the suspension fully compressed on the passenger side there is still three inches of clearance.
During the time bodywork was being done there were a few days I worked on the wheel well portion of the cab. To keep the tires from ever
rubbing against the cab I notched the edges with a plasma cutter.
After the rough cut I cleaned up the edges, then proceeded to create a paper template for a new edge.
Then I transfer the template onto a piece of 16 gauge sheet steel.
With a sheet metal break I bend the strait edges accordingly. Then I use a body hammer to beat each little tab into place then tack weld it.
As you can see by the number of small tabs this took a long time. The back of the cab has ridges making it very difficult.
Once fully in place I welded up every inch and repeated on the driver side.
When finished I sand blasted and smoothed the edges with seem sealer.
Once the truck was back together I took it out for a test run. Part of the test was to see if the tires would rub or even come close.
With the suspension fully compressed on the passenger side there is still three inches of clearance.
#307
05-27-2009
Join Date: Jun 2005
Location: Ottawa, IL
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#312
05-28-2009
Join Date: Nov 2008
Location: san jose, Costa Rica
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#313
05-29-2009
Join Date: Jul 2008
Location: Temecula, CA
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Thanks guys! The camper looks much better than the concept photos I did.
Onto finishing the bed's supports. The last changes to the bed
only consisted of the exterior sheet metal and not any
structural support. I borrow a rolling frame to work on the bed
easily.
With heavy gauge sheet steel I form a new front support.
The front support will tie into the bed floor and the front portion.
With the sheet metal being rusty from swamp coolers I toss the new
support into the sand blasting cabinet.
After sand blasting I paint the inside to protect from future rust
since I won't be able to paint it after its welded on.
Onto finishing the bed's supports. The last changes to the bed
only consisted of the exterior sheet metal and not any
structural support. I borrow a rolling frame to work on the bed
easily.
With heavy gauge sheet steel I form a new front support.
The front support will tie into the bed floor and the front portion.
With the sheet metal being rusty from swamp coolers I toss the new
support into the sand blasting cabinet.
After sand blasting I paint the inside to protect from future rust
since I won't be able to paint it after its welded on.
#314
05-29-2009
Join Date: Jul 2008
Location: Temecula, CA
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Now I weld the bottom of the support into place.
Then with vice grips I clamp the sheet metal to the support and slowly weld all of the spots welds previously drilled out.
To create the rounded corners of the wheel wells I cut strips of steel and bend them into the rough shape.
Then I go crazy with spot wells to fill the area with material. Kind of ugly, but neccesary.
After the welding madness I grind everything to the correct shape.
Then with vice grips I clamp the sheet metal to the support and slowly weld all of the spots welds previously drilled out.
To create the rounded corners of the wheel wells I cut strips of steel and bend them into the rough shape.
Then I go crazy with spot wells to fill the area with material. Kind of ugly, but neccesary.
After the welding madness I grind everything to the correct shape.
#317
05-29-2009
Join Date: Jul 2008
Location: Temecula, CA
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Now its to extending the wheel wells to reach the front of the bed. I create two paper templates that fit the curves.
I then cut sheet metal to the templates pattern.
Using a rubber mallet and a hole dug in sand I beat the sheet metal close to the correct curve.
Then I slowly weld into place.
And repeat with the second half.
I then cut sheet metal to the templates pattern.
Using a rubber mallet and a hole dug in sand I beat the sheet metal close to the correct curve.
Then I slowly weld into place.
And repeat with the second half.
#318
05-29-2009
Join Date: Jul 2008
Location: Temecula, CA
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#322
06-04-2009
Join Date: Jul 2008
Location: Temecula, CA
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Glad I could be an inspiration to ya Ciaran!
Back to where I left off...
Another piece is made from the template to cover the other side.
When every piece is fully welded I begin grinding down the welds. Then sand blast them.
Using seem sealer I smooth out the welds.
I then mask off the fender and spray bed liner in both wheel wells.
Back to where I left off...
Another piece is made from the template to cover the other side.
When every piece is fully welded I begin grinding down the welds. Then sand blast them.
Using seem sealer I smooth out the welds.
I then mask off the fender and spray bed liner in both wheel wells.
#325
06-04-2009
Join Date: Jul 2008
Location: Temecula, CA
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Now I finish off the front support on the inside of the bed. I start by removing paint for clean welds.
Then cut and bend sheet steel to fit.
And weld into place.
Next I drill a large hole through the entire support beam, where a piece of steel tubing will be placed. The tubing will keep the sheet metal from crushing once the body mount is bolted down. With most of the camper's weight being up front, I use thicker material.
Then cut and bend sheet steel to fit.
And weld into place.
Next I drill a large hole through the entire support beam, where a piece of steel tubing will be placed. The tubing will keep the sheet metal from crushing once the body mount is bolted down. With most of the camper's weight being up front, I use thicker material.
