Dylan's tray build - lots of pics

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Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 12:48 am

So I've been coming on here for a while now picking up heaps of good tricks and ideas and learning a lot a long the way so I thought it was about time that I gave something back and did a build thread on the custom steel tray I've built for my 2007 ML diesel. You'll notice some very distinct similarities to the just powder coating trays that Homer and a few other members are running. I got in contact with Brett from just powdercoating earlier on in the year in hope of buying one but at that stage he was not manufacturing them for market and was more the happy to send me through some basic frame sketches and sizes and I went from there. I'm a boilermaker by trade and work up on the mines in WA and was working mainly on the tray in my time off, it took about 4 months to build. It's just over 1400 long and about 1800 wide. The frame is built entirely from 2mm RHS and SHS tubing.

Here it is in the early stages.
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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 12:54 am

Starting to take shape with the headboard infill in, sides and latches on and centre drawer in.
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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 12:56 am

Centre drawer in operation.
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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 1:00 am

I didn't have access to a pipe bender to do the trimmings around the headboard so I just cut and welded all the angles. It took a while to get everything right but the end result was pretty good.

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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 1:04 am

All fitted on and ready for powder-coating. The side toolboxes I purchased off a local company they were a really good price and are a handy size for storing recovery equipment, compressor etc.

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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 1:08 am

Back from powdercoating.

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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 1:13 am

Canvas canopy on, I'll take some pics of the frame I made underneath the canvas I just haven't got round to taking any yet, I was in a bit of a hurry to get the canvas on ready for a trip. I knocked up the little RHS frame for the RTT as well. It was ready only hours before the trip literally went on with wet paint still :lol:

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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 1:20 am

Last but not least some pics of the finished product home from the trip. Really happy with how it all turned out, a lot more user friendly than the old tub. I'm currently building a dual swing away rear wheel carrier/tow bar so will post some pics up when it's done.

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Re: Dylan's tray build - lots of pics

Postby BillMcQuade on Sun Dec 07, 2014 4:06 am

Nice work. :D
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Re: Dylan's tray build - lots of pics

Postby baito on Sun Dec 07, 2014 4:09 am

Looks great mate,,very similar to my just powdercoating one, good job
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Re: Dylan's tray build - lots of pics

Postby Bazzer87 on Sun Dec 07, 2014 7:39 am

That's awesome! Looks so good, well done mate
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Re: Dylan's tray build - lots of pics

Postby 4wd26 on Sun Dec 07, 2014 7:51 am

that looks real good
looks like you have thought of everything 8-) 8-)
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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 9:06 am

baito wrote:Looks great mate,,very similar to my just powdercoating one, good job

Yeah mate that headboard design is all Brett's hard work he's put a lot of time and effort into getting it right to match the triton cab and I reckon he's nailed it. From the headboard back it's quite different though, shorter and slightly wider and with the construction being all out of RHS it is a bit heavier but I'm confident it will take a pretty solid beating.
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Re: Dylan's tray build - lots of pics

Postby TUF909 on Sun Dec 07, 2014 9:10 am

What does it weigh do you know?
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Re: Dylan's tray build - lots of pics

Postby dan.batto on Sun Dec 07, 2014 9:38 am

Awesome job mate, looks great
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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 9:52 am

TUF909 wrote:What does it weigh do you know?

Not 100% sure but I think it'd be somewhere in the 150kg mark, floor is 3mm Ali checker. It definitely rides better now with a bit more weight on the back axle. I've got ultimate HD 2" leaves and it was a bit stiff with the old tub.
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Re: Dylan's tray build - lots of pics

Postby TUF909 on Sun Dec 07, 2014 10:00 am

Yer ok. More than I would have thought. I'm just calculating mine up that I'm about to start building and it's looking at under 90kg. That's without the alloy cage though.
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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Sun Dec 07, 2014 10:06 am

Yeah, the centre drawer is made from 1.6 galv sheet and there's a enclosed box all the way around that too, the canopy frame, side tool boxes, drop sides etc it all ads up. The tray frame itself weighs bugger all it's all the extras.
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Re: Dylan's tray build - lots of pics

Postby TUF909 on Sun Dec 07, 2014 10:08 am

That's true, it adds up.
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Re: Dylan's tray build - lots of pics

Postby Duck on Sun Dec 07, 2014 10:48 am

What a machine looks great :) Great skills when tuff is finished we will have a weigh off behind the incinerator :lol: :lol:
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Re: Dylan's tray build - lots of pics

Postby Homer on Sun Dec 07, 2014 12:14 pm

That looks awesome mate 8-) great work!
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Re: Dylan's tray build - lots of pics

Postby mattz on Sun Dec 07, 2014 1:51 pm

Well done mate. 8-)
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Re: Dylan's tray build - lots of pics

Postby bretto64 on Sun Dec 21, 2014 8:18 am

Hey dylan nice work.just a couple of questions for you.im brett by the way and new to the forum. I want to put a similar canopy on my new ute with ally tray and rolled 3" front rack follows bodyline like yours. Question is with the side curtains hanging. at the angle to follow the bodyline do you find they suck in at highway speeds or are they pulled tight enough with the elastics to stop that. Also cant quite see in the pics are the support legs for the camper in their own pockets in the canvas or is there some clever sewing to waterproof where they come through the canvas.
any advice would be much appreciated
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Re: Dylan's tray build - lots of pics

Postby bretto64 on Sun Dec 21, 2014 8:20 am

Hey dylan nice work.just a couple of questions for you.im brett by the way and new to the forum. I want to put a similar canopy on my new ute with ally tray and rolled 3" front rack follows bodyline like yours. Question is with the side curtains hanging. at the angle to follow the bodyline do you find they suck in at highway speeds or are they pulled tight enough with the elastics to stop that. Also cant quite see in the pics are the support legs for the camper in their own pockets in the canvas or is there some clever sewing to waterproof where they come through the canvas.
any advice would be much appreciated
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Re: Dylan's tray build - lots of pics

Postby Dyl383 on Fri Jan 16, 2015 8:46 pm

bretto64 wrote:Hey dylan nice work.just a couple of questions for you.im brett by the way and new to the forum. I want to put a similar canopy on my new ute with ally tray and rolled 3" front rack follows bodyline like yours. Question is with the side curtains hanging. at the angle to follow the bodyline do you find they suck in at highway speeds or are they pulled tight enough with the elastics to stop that. Also cant quite see in the pics are the support legs for the camper in their own pockets in the canvas or is there some clever sewing to waterproof where they come through the canvas.
any advice would be much appreciated
brett

Hey Brett canvas and elastic is tight enough that It doesn't suck in at highway speeds. And as for the tent it uses the ladder as legs when it all folds out which is under the cover.
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