130 DC Trays

I still have a few things to finish off, well a lot really, but this is all DIY and ticks all the boxes I want.

To do:
Under tray boxes
Under tray rear drawer
Mesh inserts on doors with canvas storm covers
Roof rack
Tyre carrier MkII
Upgrade from the internal beta phase wiring set up.
Side ladders
Work lights
Internal dog box

Might be some ideas in this for someone.

https://photos.smugmug.com/4BD1T/i-B..._125352-X3.jpg
https://photos.smugmug.com/4BD1T/i-4..._165431-X3.jpg

https://photos.smugmug.com/4BD1T/i-V..._170439-X3.jpg

https://photos.smugmug.com/4BD1T/i-m..._170211-X3.jpg

https://photos.smugmug.com/4BD1T/i-R..._110824-X3.jpg
https://photos.smugmug.com/4BD1T/i-5..._164453-X3.jpg
https://photos.smugmug.com/4BD1T/i-N..._172612-X3.jpg

Continued....

https://photos.smugmug.com/4BD1T/i-v..._144058-X3.jpg

https://photos.smugmug.com/4BD1T/i-9..._175006-X3.jpg
https://photos.smugmug.com/4BD1T/i-g..._134358-X3.jpg

https://photos.smugmug.com/4BD1T/i-N..._121524-X3.jpg
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Some pictures of my mounting system since they are missing from the original post.

I made up a bar that supports the front of the tray and bolted it using insertion rubber to the front tray mounts. It's welded to the tray but has a degree of flex in it.

Attachment 147590

The rear of the tray is rigidly bolted to the rear crossmember

Attachment 147591

The intermediate mounts use some valve springs from a C series inter truck motor

Attachment 147592

Attachment 147593

This setup seems to have worked for 3 years without damaging the chassis with a very rigid tray.

Regards,
Tote

Front and rear mounts...the intermeadiate supports are sandwiched conveyor belt held in by compression same as some of the cab supports.

https://photos.smugmug.com/4BD1T/i-X..._055937-X3.jpg

https://photos.smugmug.com/4BD1T/i-9..._060033-X3.jpg

Fubar - any idea how much the tray/canopy would weigh?

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Originally Posted by Ranga

Fubar - any idea how much the tray/canopy would weigh?

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Oi, what wrong with your Toyota tray.....

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Fubar - any idea how much the tray/canopy would weigh?

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Not sure....I lifted it on and off the truck solo (end at a time) and I'm no gym junkie. The steel tray I had on previously I had no chance at lifting it up like that.

When I ran the calcs the difference between a 3mm alloy unit and a RHS with light alloy skin was 30-40kg.

For the most part the RHS is 1.6mm except for the bulkhead uprights and ROP's over the kids which is 5mm.

The alloy on the doors is 2mm and the rest is 1.6mm. The floor is FormPly but it's not panning out the way I thought and I will trade it for 2.5 or 3mm check plate.

Truck weighed in at 2650kg for the engineering certificate with a 4BD1T fitted, MXA-5R gearbox, aircon, bull bar, rear seat mods (added 30kg), two batteries, winch, LR sill tank, side steps, 80lt fuel, full tool box in the tray etc

It's no ultra lightweight, but it can handle a decent load without distorting which is important to me.

If I get enthused one day I might find my spreadsheet, update it to match the exact build and calc a reasonable estimate. I do know that DIY was about 7-10 grand cheaper!

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Originally Posted by weeds

Oi, what wrong with your Toyota tray.....

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Nothin - it's unbreakable [bigrolf] Just curious about weight, my alloy Toyota can be lifted off by 2 blokes (without the custom girders).