Hey all i got asked how i did my half cab, flat bed "cutting" on my zuke. I know there are a few (here on pbb) who have dont this so maybe we can gather up all the cool tip and gotchas to make it easier for others.

Sorry the pics are so big ill crop them tonight and edit my post.. I had these posted mainly for my cage to solicite input..

First A pic....

http://www.yager.net/zukin/new/dscf0276.jpg


Here is what i did. First thought long and hard about my plans theres not much turning back once you start.

I decided to cut at the angle seen as it look good with the door angle. I can't tell you the exact measurment cause i just started cutting. But headed straight for the targa/tub joint.

I used a straight edge and marker then used a cut off air tool to make the cut. A recip saw would have been easier in spot but use what ya got. I sliced the small corner bracket up there and added some small welds to reinforce it. To be safe I cut a ways out from the actual floor cut tilli was sure of my plan.

When the tub was off i remove the tail gate and to my surprise it fit in there nice and tight with ~1/8" gap on each side. I then cleaned up the opening so it would set in there smoothly, notching some on the wheel wells. (ill post more pics tonight when i get home) Now the floor pan has a ~3" "shelf" where the tail gate sets on. The rear lower lip on the gate over hangs this shelf edge keeping water outside. I welded it where i could and Ill use some undercoating when i get the inside cleared out or parts.

I thought for a few days on how to cap the corners, ive seen a few nice jobs and a few "ok" jobs. I wanted it to look good but im not a body person and i didnt want bondo to crack off the first hit it took. my first idea was to use the original rear corners, but the raidus of them was too large to fit my working area. So i got a small piece of 22ga from lowes and first tacked it to the tail gate, then pulled it to the side skin i marked it where i could and tacked it other spots. Then as I went i cut off the extra to leave me with the new "corner" the lower part has a nice bend and for that i just did a basic pull/tack... repeat operation. Then cleaned up the wleds a bit (they are not smooth) then some rustolium gloss white. Start to finish 2.5 hours EACH side. But its (will be) waterh tight and look acceptable, welding tin is a pain even on my lowest setting... A pulser gun would have been the bomb. Im pleased with my work as it came out better that I expected.

Plans are take an old soft top with bad corners and make a back cover. Ill use some lexan or vinyl for a small window and snaps to hold it on. I have a bikin top that seals fairly well in the front and it will simply overlap the rear part when its done. It will be fine for the use it sees on road...


Good:
-I now have a small area behind the seats to stash junk out of sight.
-No one else in town has one :-)

Cons:
-The seats will loose some ability to recline (more if back window on)
- I get asked "what is it" alot (and it hasnt moved since i cut it)
- Ill prolly be stoped more often by Johnny Law


have fun cutting ill post more pics later
-yag

Originally posted by zukipuke

- Ill prolly be stoped more often by Johnny Law

I know this is a little off track, but you guys may find this interesting...

You've all seen the pics I posted of Jayon's chop job. Well, he's got lights and all mounted on the truck, but not a stitch of sheet metal over the rear tires. Well, Sunday night he made a run into town to see how it drove on the highway and clock some run time before Moab. He came by to visit, then left my house about 10pm, made it about 4 block and the truck died! He's setting at an intersection (not a major road, small-med sized OK town), desperately trying to find out why it won't start. He turns around and a local cop has pulled up behind him. :eek: He's thinking 'oh sh!t'.....

The cop comes up, looks the truck over asks what is going on (and what it is :) ). Jayson tells him it died, and he thinks a wire came loose. The cop asks, is this thing street legal...... Jayson replies, I think so, it's got lights, tag, etc.... The cop looks it over some more, says, 'the bumper height is probably a little high, but I'm not going to measure it'... He helps Jayson push it over into a parking lot, and gets in his car and goes on.... Whew.. What do ya know, there are a few cool cops around.. :D :D (sorry CA guys, we're keepin' them here!)..

i think yer doing a damn fine job so far,Yag!
looks like you have a good eye for detail, and are willing to put the effort in to make something very cool.:cool: :beer:

Let's see some more pics!

I like your ideas!

Dave
aka Shogunator

Originally posted by zukipuke
then used a cut off air tool to make the cut. A recip saw would have been easier in spot but use what ya gotEver used an Air Body Saw? Looks like an air-powered mini sawzall the size of a die grinder. Those things are sweet. Clean cuts, and they go through sheetmetal like buttah.

Also cool cuz most of them are front exhaust. So they blow the metal filings off the work as you use it. Drool...
http://www.kctools.com.au/suntech/fl020005.jpg

:grinpimp:

http://tellico.off-road.com/wwwthreads_uploads/763441-LC56a.jpg

Hey oilburner what size is that alum tool box on the back. Can you get enought junk in there? It looks custom?

I've been tring to figure out what size box i need so i can incorporate it into the bed area and reduce the floor material...

Must be nice to not have to worry about RAIN !!!!

Dr. Evil.... im so over spent for this month.... even a $30 tool is pushing it... So far this year I've droped $ on a pro-tool bender, hobart 185, notcher, Crapsman toolbox, small band saw, + actual zuke parts (ok toy parts) 5.29s spool, L/R, Kong steering Arms, some way cool 7/8" steering parts and my list goes on.....

On that note im looking for some ~plastic type material to use for some bed sides. Nothing overly strong, id use plywood but id never here the end of it.

My #2 pUter, isnt happy so i cant find the pics i had during the building of that part, if i cant find em ill snap a few more tonight...

-l8r y'all

why not just use plexiglass for the sides?:rasta:

that was one of my ideas the problem is where exactly to get it for a small sum... Lowes has some acrylic but its kinda thin. ~1/4" lexan (plexy) would be the bomb and hold up well.... Any ideas?

-yag

Dont no exactly what yur lookin to do but what about an old pup truck Bedliner. just an idea

Originally posted by zukipuke
that was one of my ideas the problem is where exactly to get it for a small sum... Lowes has some acrylic but its kinda thin. ~1/4" lexan (plexy) would be the bomb and hold up well.... Any ideas?

-yag

Try your local glass shops and see if they can hook you up with some lexan. I used to work at a place called Austin Glass & Mirror, and we did mostly commercial buildings. We always had a bunch of lexan scrap left over from different projects. Tell them what size you want and normally they will cut it for you. If your lucky they might just give it to for free. We did this alot just to make room in the shop. Glass shops are also a great source for sheets of aluminium.

Originally posted by zukipuke
Hey oilburner what size is that alum tool box on the back. Can you get enought junk in there?

I picked the alum. box up at a local camper-shell/toolbox place. It's approx. 12" x 12" x 30" It will hold a decent ammount of stuff - I plan to mount my CO2 bottle in there (with a pivot so it can stand up to use) and my tools & spare parts will go in a compartment under the bed, directly behind the cab. (when I get around to finishing it)