My Steel Tray Build - Built completely in my backyard!

so I've been wanting to build a tray for this dude for ages now but I haven't had the motivation but you haven't had the time but so far I've got motivation no time let's see how we go [Music] [Applause] [Music] [Music] thank you [Music] thank you foreign [Music] for this shoot just wanted to make it this a little bit narrower a little bit shorter I wanted to um sort of cut off the edge sides I think they call it dovetail and I'm not quite sure just um having tail lights nice and recessed in so when I back into Banks and do stupid stuff I don't bend lights and brake lights all the time I'm going to have little tray sliders around the side and hopefully yeah hopefully it looks apart and stays up to the test of um silly activities let's see if we can um turn some pieces of metal into um what resembles a tray how hard can it be so hit up a mate at a local steel supplier um thanks Ethan gave us a hook up here so we've got some bits and pieces I um sat down and worked out kind of what I needed on paper I roughly made some measurements and things and a bit of a mock-up drawing and got some a bit of a cutting list of what they call it so fingers crossed that's all I really need besides that tail lights and a sheet and then yeah turn it into one of them so I started off just doing some basic sketching it's quite easy to make actually um the tray that I wanted to build to scale so that's sort of one tenth where it should be it makes all pretty easy so when I want them to work out how much the oil needed basically just measured it um with it being one tenth scale was really easy to figure out my lengths and things so just doing some drawings give me a bit of an idea of how it would all look part of the result that I'm pretty happy with made a bit of a cutting list this isn't actually complete there's a few more lines down here that I ended up getting as extras but that gave me a bit of an idea of what I needed worked out widths of the cab and width of the train where I wanted everything making sure it would all cover the tires so it gave me a bit of an idea there so what I'm going to do is just basically lay everything on the grass make sure I've got everything I need and then um yeah start making some measurements and cutting things up and hopefully weld themselves together all the bits too I've got uh three mil so I went three mil 50 by 50 3 mil 75 by 50 and this big dog over here it's three mil 150 by 50. that's going to be my um spacer basically between the chassis Towers or the tray Towers whatever you want to call them to the tray so oh and 32nb for tray sliders just medium wool no idea how thick medium wool is but it's about about that thick I got these bits which I got the wrong bit because I'm a spud I think I got 40 NB instead of 32nb that's all right I'll go swap them out for the ones I need so I've laid it all out on the ground it's giving me a bit of an idea of how everything's going to go together so this is going to be my headboard um it's all going to be like the flat section here it's going to be upright there um turn that into a bit of a headboard sort of arrangement that's obviously just a flat tray section tray sliders I'm going to fold up this section at the back here I'm going to turn that into my table light number plate Arrangement but yeah seems that I've got everything I need so I've just laid out the basic shape of what it's all going to look like to try and work out my spacing for the little tray supports also just put me spare in the mix as well just to try and work out distance between these two for when it's um all flexed up and up into the guard so I don't want the tire striking any of these supports and rubbing so hopefully that's in the right spot there looks to be enough clearance either side I start welding things together and seeing if I can make it a big blue square [Music] thank you so basic sort of shape of what it's going to be um it's actually a square something out too I don't know how I managed to work that out but I must have float it now it's going to try and work out um what I'm going to do with these rear section I'm going to try and get a bit of a um that dovetail sort of shape going on it which would be kind of cool so I'm gonna have a bit of a play around and see if I can get this 50 by 50 to put up against the 75 by 50. it's sort of a bit of a a bit of an angle like that and then continue another angle there across and then back again so this section in here from here to here I might actually monitor that joint never done that before but that'd be kind of cool see if we can work that out but this one here might be pretty easy I reckon I'll just lock a bit off the end there to butter that up and build an end plate just to fill that Hollow section in there give it a bit of strength and make it all um all neat and tidies so I've got this fancy thing for Bunnings it's like a digital angle gauge or angle on what I want to know what the hell you call on but it's pretty so you can just loosen this little dial here and you can just adjust your um angles you want to measure super handy so I've got um the distance I've got the angle that I wanted there mark it up on the machine so cold cut on this drop saw and hopefully that'll be close to what I want it to be check that out actually works sick good little investment that one so now I've got that um angle cut there fits in there the way I wanted it I've measured out the distance that I need for the little tail light recess and now I need to do a miter join I want to cut or whatever you call it to make this section here go back along to meet up with the other side so the angle there that's required is 15 degrees what I'm going to do my mark just a straight line down the middle to Mark a bit of a reference point then seven and a half degrees each side of that I'll make two lines going from the center being out slightly so cut both those and then once I close the gap up I could have my 15 degree Bend hopefully [Music] foreign [Music] tax in there for now just to hold it so it's um thing on 15 degrees so now what I'll do is I'll just come to this end work out where I'm gonna cut my angle there work out where I'm going to um do the other minor joint and then I'll have a rear section [Music] [Music] so I've got this corner cut that angle is all set up that angle is all set up now I just got to work out where I'm going to chop this one off here so I'm just gonna get the Nico do a little line underneath give it a chopping hopefully that fits well actually fits pretty good all the angles seem right pretty snug at each end so I'll fill in these worlds later on when I wear out the rest of it but for now I'll just tack the sides keep it all in place that'll stop underneath for moving and then on to the next step so I've just um flipped the Traders onto its side now I'm going to start um welding out just these Corners down here and I'll flip it over this side um just basically put it on all four different angles to get all my welds sorted that way this main shape can stay for this and it won't warp or do anything weird as I wrestle it around and try and get it on my trailer work at a few more measurements and things and then um I've got to start on some mounts and work out how to mount it to the tray then then somehow work on getting this freaking thing off not really sure how to do that yep got a little bit of an issue over here I am I'll bug it up and ordered the wrong bits so I'm currently waiting for some knuckle Stars at the moment I ordered some ARP ones some three flash runs about I ordered this friggin Club studs instead so anyway I got upgraded Hub starts in the art you know I didn't need them but waiting on some ARP ones because this freaking thing snapped so once I get them not gonna move the ute to somewhere where I can get the tray off and then put that on there work out the headboard and stuff but for now I'm just guessing [Music] [Music] [Music] all right [Music] so I've got all Corners welded all sides welded besides the top bits these turned out great these body thing so I'll give that a bit of sand up then make it all look pretty I guess one piece but now I'm going to try and work out some tray mounts for underneath it and then get to the stage where I can pretty much lift it on the Ute and then then the exciting bit is mocking up the headboard and then once it's on the Ute I can mock up the rest of the tail light sort of section and then we're getting close to hit looking like a real tray this is sick now I just worked out my tray mounts I'm just going to go basically from this to here for the front two 50 by 50 OHS three mil again and then for the rear section the tray Mount is basically dead in here in the middle of those so same deal 150 by 50 box just across here about 300 mil long about 800 ish for the front I've got some gal stuff that's actually all I had but it's going to work it good anyway because more than likely it's going to remain open so save it rusting out Gail's probably the best thank you [Music] foreign [Music] supports or mounts whatever you want to call them they're all cut up and ready to go I'm going to do some angled brackets just off here just down to give it some sort of side support as well okay so you know put the car into a bank or anything well not in case for for when I put the car into the bank um say they sort of rolling over or getting squished and squashed out or whatever do that a bit later though I'll just weld them in place for now and I'll flip the tray over and start to work on this little tail light section they'll give me some measurements as well for um some sheets and things I need to order later and I'll get back around to bracing these up a little bit later [Music] [Music] there we go the try mounts all fully welded yet all um Four Corners around them get them as strong as I can I guess and then um I worry about bracing it later once it's actually on the Ute in case there's something underneath the um tray that's going to get in the way like I'm going to fit the water tank in this section here so I'll have to work out where I can put the pricing same with the rear but I reckon that might do us for today another track tomorrow and see if I can get this um tail light section fabbed up and then yeah eventually we'll get the parts for this thing so I can put a wheel on it and then um yeah take a little drive to um a yard wreck and forklift the tray off and then hopefully put that big blue square piece of Steel on it and uh hopefully it fits or we're back into it again today we're gonna try and fabricate up this rear tail light section I'll make this little top section stick it on get mangles right and try and work out what I'm going to do with these little corner tail light section here and I'm going to make um obviously hit up to about this section here so I don't see my training out so I have to raise it up 150 mil or something but make that work what are you doing mate fluffy Apprentice okay so these tail light sections are all just sort of sitting Loosely in place just held in by the magnets at the moment it's giving me a bit of a idea of the height and what I need them at um now basically just getting my angle here for this little rail which I'll transfer onto this section which will be my rear piece I'm gonna sit in there like that just recessed and that'll um finish up the towel section all these rhs shs sections have like a little seam on them as you can just see in here if I can get the camera to focus and that seam when you paint it it shows up so you want to have that same towards the back you don't want to have it visible because when you do paint it it ends up looking like this and every time you look at it it annoys the absolute crap idea sorry approach it [Music] of course there we go that back section's all together now which is kind of sweet what I'll do is race around using this little device here let's make sure that everything is the same level which is pretty good finish off welding around [Music] [Music] [Music] so it seems like it's like an Unwritten rule that every time I try and do any sort of fabrication it's like piercing down rain had to I got for a bit here everything started to get buddy where benches all got wet which is getting all rained on even though we've got a roof over here rain was like coming in buddy sideways across here for a sec but anyway what I'm going to do now I've got this little he's over while I was out waiting for the rain to clear oh this little orbital heat sand a thing eh I'm gonna Chuck some sandpaper in it and um yeah to start smoothing out these make it all look nice and flush and then um I reckon that'll do it for today and I'll get back into it tomorrow got a little cheap orbital for Bunnings got some Sandy pad things basically just going to go over it make all this nice and smooth have a little bit of a go at it last night but in my Rush um I actually put the left side and the right side and the right side of the left side so now like I was saying not to do I got this buddy seam and when I paint it it'll annoy the out of me so I'll um yeah I'm not going to unstitch it I'm not gonna unweld it and cut it out whatever so I'll just get the sander now with the sand of that all flat so that all looks nice and pretty but um that's this morning's little Mission let's get stuck into it again [Music] [Applause] [Music] so I've given these a bit of a sand down they're looking better pretty smooth now I'll um hit him a bit more when I get it back up on the ute finally it's a little bit higher then I can work on a bit easier but now I'm just going to try and work out what to do with these Corners [Music] um it's kind of been putting it off because I'm not really sure what the best way of approaching it is but what I was thinking is I was just going to get the grinder and just slop it off try and get this section here as flush as I can with this part but I'll just make a little square that sits in there I'll weld it up and then hopefully with a lot of this machine and a lot of that machine I can get it to um just look nice and flush and smooth here's the plan oh yeah see how it goes a bit of time consuming exercise but it's got to be done it looks looks pretty weird look at that stuff like that so well see what we can do see if we make it pretty [Music] so I've just got a bit of a rusty off cut of something I'm gonna get the right shape and cut the square out and then basically recess it so that's flush in there water on the edges and then yeah cut that off should work should work good a bit Overkill but needs to be strong so I've got my little piece in there it doesn't fit too too bad and get it nice and nice and flush I'll just tack it in place double check it and then weld it out drawn it back smooth it off and then do the other side [Music] all right yeah it's turning out pretty good not too bad once again once you get on the back of the Ute I'll be able to have a better angle at it and I'll um try and get a little bit better again but come along good now to um do the other side I won't bother filming it because you've seen one side I didn't see it again [Music] foreign [Music] [Music] off and on what's not raining I'm just gonna go around with this tidy up formula worlds and then I'm going to give them a bit of a coat with um just one of these not really sure what's better yet whether I'm going to use this ink it the gal Max they both look pretty good products I've used this one in the past before it's been all right never used this stuff before but I've read it again and see which one can persuade me which one to use and then I'll touch up all the welds all the joints that way it's sealed and at least if it keeps getting rained on it's not going to um make it harder for me to paint down the track [Music] all right [Music] cool so I went for a drive got me sheets hopefully two sheets here the remainder of one of the sheets can be for the back and then the other clean sheet or use the entire thing for guards in the headboard [Music] [Music] so I'm gonna make a rear sheet first basically it's got it joined up just in the center of a 50 by 50 so I can rub the two sheets together I will make the front one last but now all I'm going to do is get an echo and then just um draw my line as a bit of a cutting template along the back there to get the shape get the corona back out again and chop it into the shape it needs [Music] foreign [Music] sheets cut for the um the front and rear that's all sorted and I built up my tail light section of the number plate section just off some off cuts and then I'll weld those in so I'm going to leave the top tray seconds off I won't weld them on for now I'm just going to um basically keep it as light as I can so I can lift it onto the Ute when I get that back in one piece so on to making some tail light fill in things [Music] these are sheets are cut up they're all good to go not the best shape but they fit in there nice and cover up that little hole so best I could do with some off cuts I'll um just give them give them a quick little spray with some world through primer that way the section that's up against here isn't just raw so if moisture gets in it doesn't bleach out rust so give it a quick spray paper to draw and then I'll um wheel them on [Music] foreign [Applause] [Applause] [Music] [Music] Tes just so that way the holes are there and it's gonna have to drill through fresh paint once I paint it put some stitches on the back for now reckon that's what it's gonna really gonna need I'll just um clean them up and paint them when it all cools down but that'll that'll do for today [Music] [Music] foreign [Music] few little oversights however I'm gonna have to um trim this little Mount here so we see that doesn't touch the chassis that'll be easy it's funny like that that'll sort that problem out um I'm gonna have to weld me other tray man on because it was broken that's not gonna be a big deal as well the top back on that but over here something I didn't think about is the tail section hangs five or so mil lower than the actual chassis Mount so I've got a gap here as that's touching hard on the chassis so I can either move it back a bit to clear but then I run out of length on the mounts which might work and then the headboard distance is going to be too large so I'm gonna have to space a tray up with something I'll just get some little poly um wedges or something or little spaces I got these which I made for the original tray that come off it just get a bit of extra height so maybe I can cut them in half and his face to tray up a little bit I didn't really want it I wanted to have it nice and low um it's already probably 20 30 mil higher than that trailer had on it before but gonna have to if I want to make that clear I'll um try and get just a tiny tiny little Gap out of it but that might be a drama I'll be able to sort that out but still happy it's on happy with the width got a little bit of poke there which will um I'll be able to fill in with those um with a 32nb pipe along the side has like a chassis there's like a tray slider which would be sweet and then the tube guards will cover up everything but it's looking good getting closer so what I'm doing here basically trying to get my headboard height worked out so I've got it so the band's going to start around about where that body line is just got a little angle gauge here again trying to work out the um yes it's like the headboard angle really I'm thinking 18 degrees where that sets pretty much bang on the money so um yeah mock this section up and see what it looks like [Music] thank you [Music] thank you I'm just mocking up one side of the head but what I've got the two sides I've got them a nice little 90 with um the flat Bard in the bottom and now I'm just looking at the top angle which is pretty easy the angle is 108 and then you just halve it say 54 here 54 here and it should all right up and be nice and flush here's the plan anyway and then I work at length light artist do one end make sure that's going to work then I'll try and get my uprights on each side make sure that's actually the height that I want and then um yeah work out this top length tack it in place and then uh yeah the headboard can be done for now I'll actually get that 50 by 50 that's on the ground there that'll go probably somewhere along here and then I can sheet it which will be the little sort of backboard protection thing for the cab or whatever and then I'll just tack that in place it won't actually weld it all properly until I get the tray back off again so I don't wreck the pain on the Ute and then I'll start moving on to some Trace sliders [Music] foreign [Music] just gonna sort of get it flush with the magnet and what I'm going to use I'm going to use this little tool here basically I'll set it so you can see the screen it's at zero now and it just lets me know degrees so what I'm going to do because it's magnetic it's going to stick it on here and then when I get this section let me figure out to do it one-handed and film but I can actually get this piece here nice and level filming but that'll make sure that that's um flush and not um on the piss [Music] so the first attempt was a bit hard trying to hold it instead of it but what I've done is I've got this here so I can get just a bit of a rough height so it doesn't drop down also got my little magnet in here to get it nice and flush or as flush as I can get it and then happy with it now so that's dead level there and then I'll stick that on not too bad I'll start placing some more taxes to steady because I've only just got one in there at the moment just holding it all together but um I'll run around with a few tacks and see if I can keep straight [Music] [Music] um sweet so I got all the um well two of those headboard pieces cut up um I weld them on when it's all off the car back on the ground so for now I've taken it off so it's less weight to lift what I'm going to do now is try and work out my um grub bars or brush bars or tray sliders whatever you want to call them basically it's going to get a 90. um 32nb pipe just follow it along I'll work it with I can just use the 90 as it is or whether I need a shimmy bit off the back to try and snug it in a little bit more to the tray but kind of one of the tires completely covered up if I can I'm playing around with this and see what I come up with [Music] [Music] so we're gonna do a little bit of a change of plan we're gonna have to speed up the process a little bit because it's crazy enough I got a bit of an opportunity to get the Ute actually photographed in magazine so we're gonna speed up the process a bit because I'm running out of time to get this tray done I've never got three days before it fits photos taken so we've got to get this huge finished off painted and prepped and basically ready to go so Wayne giving me a hand the main priority is getting this new tray finished so try and get it welded up this afternoon either tomorrow and hit it the next day which is like cool so you trays off again got these side rails just tacked in place and then what we're going to do now is just fab up this headboard get that bit out of the way and fully weld it now it's off the ute [Music] [Applause] [Music] [Applause] [Music] [Music] [Applause] [Music] I love you [Music] [Music] [Applause] [Music] [Applause] [Music] I want you [Applause] [Music] [Music] all right [Music] [Applause] now [Applause] [Music] [Music] all right [Music] [Applause] [Music] thank you [Music] [Music] there's a few things you would have done differently when I was um building the tray one massive thing is this time it was a bit of a rush build there's a lot of stuff I would have done a lot differently and a lot neater um including you know wouldn't have run my old guards I had to sort of just quickly Chuck them in so they just held in by some tech screws only three so they're not even mounted properly but just had to get them on for that um the photos would love to um have finished off the tube guards I made a bit of a start down here but um didn't get very fast I'll eventually um finish them off throw these in the bin where they belong and then yeah get nice tube guards all tied into it I would also add some more reinforcements just through here and maybe 300 mil or something just like a bit of flat bar or whatever just to help keep that nice and strong I didn't even get a chance to work lights properly so I don't have reverse lights yet so I've got a reward reverse lights these aren't actually watered up yet I've got a Max to be a tire somehow it's just sitting there at the moment I'm probably gonna mount it something like that looks kind of cool a bit of a bit of a lean I've got my two boxes on at least anyway space cases got that all nice and neat I still got to finish up my wiring so light bars on top um rock lights underneath it stuff I made a bit of a start on my 12 volt so I got um what I'm going to run my fridge off here just my positive and nms um wires as well as just a manual override so I can link two batteries and a VSR just tucked in there neat enough for now but I've got to tidy up all that they even started this mocking up where that water tank is going to be just um got it tucked away underneath the um underneath the tray there nice little neat spot for it I think if I ever do another try as well I'll make a um this headboard section A Bit Stronger two or have a few reinforcements going down maybe another panel going from here across the bottom just to um strengthen up a little bit too also I don't need bloody um I only put one coat of paint on it too so I'd like to um eventually take it off and give it like a proper paint job I don't want to be one of those YouTuber people who is like like subscriber or whatever but it actually helps heaps um because you know it takes a lot of time to make these videos well it takes longer for me anyway because I don't really know what I'm doing then it actually does to um to make the tray which is pretty crazy because a lot of time went into that as well anyway so it does catch us next time

Channel: Haydn Kamp

Views: 80,829

Keywords: hilux, ln106, patrol, landcruiser, tray, ute, fabrication, design, camping, overland, 4wd, 4x4, adventure, custom, steel, australia, 80 series, chop, diesel, overlander, rock, rockcrawling, yota, rock crawl, crawler, welding, painting

Id: 4y7zMq6vlhs

Length: 40min 50sec (2450 seconds)

Published: Tue Jun 20 2023