Convert Dual Cab HCPU into tray back

[iClick]

Hi Folks,

I'm searching for a 130 Dual Cab Defender to go under my Aluminium trayback canopy.
https://www.aulro.com/afvb/images/imported/2012/12/898.jpg

I've come across a few HCPU versions. Is it a simple task to unbolt the tub and replace it with a alloy tray? I have in my possession a 2100mm x 1850mm alloy tray which came off a Ford Ranger (You can see the alloy tray just below the canopy in this picture.)

I imagine it will take some modification to fit it, (what happens to the filler pipe?) but is this a practical solution?

[rainman]

It's no big deal to convert to a tray back if you have some basic mechanical skills and a suitable place to do it. You might need to make up brackets out of channel of box section, and as you mentioned, some brackets for the fuel filler. You'll also need mud guards which you could make yourself quite easily, or buy from a ute/truck body parts supplier or trailer parts supplier.

James.

[iClick]

Thanks rainman - I appreciate your feedback. Glad to know it wouldn't be too tricky.

[rainman]

If you need any specific advice feel free to PM me. I had a 110 tray back which had two different trays on it in the time I owned it and currently have a 130 DC which I made a tray for.

https://www.aulro.com/afvb/images/imported/2012/11/45.jpg

https://www.aulro.com/afvb/images/imported/2012/11/46.jpg

James.

[iClick]

That looks terrific - when I do the conversion, I'd love to be able to utilise any spare space under the tray for storage. I'm looking to save as much weight as possible as the vehicle will be used to head overland to the UK in a few years and every gram saved will be beneficial.


One additional question, are all the 130 DC Tubs rated as High Capacity, or is it only certain models?

[rainman]

Lightest weight possible is always my philosophy too. I used aluminium wherever I could, but had to make the "backbone" (the grey bits in the build shot) out of steel because they had to be welded and my MIG isn't set up for it. You will end up with some good usable space under the tray ;).

I think the "HCPU" name is just marketing-type naming. I believe all 130 DC tubs are the same.

James.

[iClick]

OK - picked up the truck and the tub comes off on monday. Looking at the job tonight (friday) I realised that I haven't got a solution for the filler neck ready to go. Can anyone advise what the best solution here is. I read in another post to try and score a used Hilux one from a wrecker. Sounds like the business to me. :p

[rainman]

I don't know if this is the thread you were reading, but there are a few options and opinions listed.

fuel filler 130 ute (http://www.aulro.com/afvb/general-chat/163522-fuel-filler-130-ute.html)

James.

[2stroke]

In my quest for less weight and more space for 2 spare 255/85s I ended up going for a tray on my 130 to replace the tub. Due to quotes for supply and fit of trays being arm and leg type expensive I went to the wrecker and picked up a nice Challenge brand ally one for $300 (had to remove it myself). It was missing the headboard, which wouldn't have fitted anyhow, but included tail lights. To clear the 255s when axle meets bumpstop it had to be mounted fairly high anyway, besides I'll be fitting a poly water and fuel tank as well as a drawer underneath. I made a good bracket for the filler as high as possible (also had to remove a little bit of tiedown rail) and fillups with a Longranger tank are no probs.
Edit; I used the proper Landy filler not some crappy hilux thing. I use a Hilux for work and it's the must annoying filler in the world!

[2stroke]

Oh and the tray was removed from a Mitsubishi Triton dualcab, 1770mm long (about the same as the tub) and 1870 wide. Glad I had to make my own mounts as it was mounted to the triton with Unistrut and held on with believe it or not four 10mm unistrut nuts!

[iClick]

I don't know if this is the thread you were reading, but there are a few options and opinions listed.

fuel filler 130 ute (http://www.aulro.com/afvb/general-chat/163522-fuel-filler-130-ute.html)

James.

Thanks, yes I saw that but aside from the Hilux suggestion, most of the solutions don't suit my setup. I'll have a canopy covering all of the tray so going through the floor isn't an option.




Edit; I used the proper Landy filler not some crappy hilux thing. I use a Hilux for work and it's the must annoying filler in the world!

I know it mightn't be ideal but I need to resolve this by monday and I think sourcing a original part might be tricky. I can always address this in the future.

[2stroke]

Surely you could get one off an old series 111 at the wreckers? Biggest problem with the hilux filler is it's much smaller than the Landy tank filler tube. Also with a 127 L tank in mine it's handy to use the hiflow diesel bowser.

[iClick]

If I can find one that would be awesome. Not sure how I'll go over the weekend. I'm in South of Sydney in the illawarra.

[vnx205]

Surely you could get one off an old series 111 at the wreckers? Biggest problem with the hilux filler is it's much smaller than the Landy tank filler tube. Also with a 127 L tank in mine it's handy to use the hiflow diesel bowser.

With the tray on my 110, there isn't much slope on the filler neck, so when I use a hi-flow nozzle, I can't take advantage of the maximum rate of delivery. In fact with some diesel, I have to be a bit cautious even with the normal nozzle otherwise it spills froth and/or triggers the auto shutoff.

If you are planning to mount the tray high enough to create storage space underneath, you may be able to get a bit more slope on the filler tube. That isn't really an option for me because it would make the camper inconveniently high.

[iClick]

With the tray on my 110, there isn't much slope on the filler neck, so when I use a hi-flow nozzle, I can't take advantage of the maximum rate of delivery. In fact with some diesel, I have to be a bit cautious even with the normal nozzle otherwise it spills froth and/or triggers the auto shutoff.

If you are planning to mount the tray high enough to create storage space underneath, you may be able to get a bit more slope on the filler tube. That isn't really an option for me because it would make the camper inconveniently high.

Your setup sounds close to what we're trying to achieve. I'm worried about the tray height creeping up. The canopy I have has a lip below the doors and a very substantial chassis which increase the access height. I can forego the storage space under the tray if it keeps the deck lower.

If it was at all possible - would you be able to give me the amount of clearence you have between the underneath of the tray and the top of your chassis. Perhaps you could measure somewhere I could check against (the bump stops?)

Many thanks, Paul

[vnx205]

My tray is aluminium with 40mm deep ribs underneath. With the standard 235/85/16 tyres, I was able to rub the tyres on the ribs in extreme cross axle situations. My solution was to remove a small section of the ribs where the tyres rubbed to give me almost 40mm more travel before the tyres rubbed.

The measurements from the underneath of the tray (not the bottom of the 40mm ribs) are:
At the front to the flat section of the chassis where the towers are mounted to support the front of the tray - 380mm.
To the top of those towers - 215mm (made up of 75mm transverse steel C section and 100mm longitudinal aluminium C section and 40mm ribs).
At the rear to the chassis cross member - 265mm.

Does that make sense? Do those measurements tell you what you need to know?

[iClick]

My tray is aluminium with 40mm deep ribs underneath. With the standard 235/85/16 tyres, I was able to rub the tyres on the ribs in extreme cross axle situations. My solution was to remove a small section of the ribs where the tyres rubbed to give me almost 40mm more travel before the tyres rubbed.

The measurements from the underneath of the tray (not the bottom of the 40mm ribs) are:
At the front to the flat section of the chassis where the towers are mounted to support the front of the tray - 380mm.
To the top of those towers - 215mm (made up of 75mm transverse steel C section and 100mm longitudinal aluminium C section and 40mm ribs).
At the rear to the chassis cross member - 265mm.

Does that make sense? Do those measurements tell you what you need to know?

Thanks so much for those measurements, when my wife brings the truck back I'll go and compare :D

[iClick]

Does that make sense? Do those measurements tell you what you need to know?

I think these measurements will be extremely useful when the tub is off and we're locating the new tray. Could I be cheeky and ask that you might take one more measurement? The height from the ground to the top of the tray where the camper sits would be fantastic. I really appreciate your help. :D


Surely you could get one off an old series 111 at the wreckers? Biggest problem with the hilux filler is it's much smaller than the Landy tank filler tube. Also with a 127 L tank in mine it's handy to use the hiflow diesel bowser.

With regards to the filler neck, I'm a bit stuck. I tried several wreckers in the area, looking for any diesel neck off a tray back ute without luck.

I had hoped to get the tray fitted on monday but without a filler neck ready to go I may have to put the project on hold for a few days until I get it sorted. It's a bugger as I wanted to use the flat tray for a job on wednesday.

After living with the 130 for a couple of days now, I do question why I'm removing such a beautiful piece of kit for a second hand aluminium tray :eek: It took this today whilst at the boat ramp, I scratch my head and wonder if I'm really doing the right thing :o
https://www.aulro.com/afvb/images/imported/2012/12/791.jpg

[vnx205]

The height from the ground to the top of the tray where the camper sits would be fantastic.

Today, with nothing on the tray and only minimal pressure in the airbags, I have 140mm gap between the axle and the bump stops. The top surface of the tray is 1010mm from the ground measured beside the wheel. When the camper is in place, it sits on 45mm wooden rails. I needed to use them to raise it enough for the drawers to clear the 30mm lip on the top of the tray.

Tomorrow I will be able to tell you what those measurements are with the camper on board and 20psi in the airbags. I will be fitting the camper in readiness for a few days in Bendethera with Tank and with Mr Ploppy and his wife and two children.

I think that with the airbags, it only settles about 20mm. I will try to remember to check the measurements tomorrow.

[mike_k]

G'Day i click,

I wouldn't worry too much about the filler neck - just use the factory one already fitted to your HCPU tub.

Thats how it was done on my tray, you'll find that the whole filler neck unbolts from the tub and then you should be able to use it and the original hose between the filler and the tank.

My filler was like this, with a fairly simple bracket to hold it welded to the bottom edge of the tray. This way you retain the factory filler and the locking cap as well. Much better that one from a ***ota etc.

By the way, I went the other way - converted the tray back to the tub, as you say a really well designed bit of kit. I've still got the tray in the shed though, just in case.....

Cheers,

Mike.

[2stroke]

I also quite liked the tub and only removed it because I needed space for more fuel storage, more than the 127 litres it already carries and the 2 255/85 spares. The tub was great in terms of keeping the payload low and the tailgate was a perfect lunch making/cooking bench but the tub was not so great for tieing loads down securely. I also used the filler out of the original tub, it is probably an inch or 2 lower and extended outboard a few inches to account for the wider tray (exhaust tube from the local exhaust shop).

[iClick]

G'Day i click,

I wouldn't worry too much about the filler neck - just use the factory one already fitted to your HCPU tub.

Cheers,

Mike.

Thanks Mike, thats the conclusion I came to this afternoon when I looked at the tub more closely. I just need to drill the pop rivets and remover the original. Can someone just remind me that I'm not doing anything to dumb by using a cordless drill near the diesel filler neck :eek: Diesel isn't explosive and should be safe enough to work around - right?


Today, with nothing on the tray and only minimal pressure in the airbags, I have 140mm gap between the axle and the bump stops. The top surface of the tray is 1010mm from the ground measured beside the wheel. When the camper is in place, it sits on 45mm wooden rails. I needed to use them to raise it enough for the drawers to clear the 30mm lip on the top of the tray.

Tomorrow I will be able to tell you what those measurements are with the camper on board and 20psi in the airbags. I will be fitting the camper in readiness for a few days in Bendethera with Tank and with Mr Ploppy and his wife and two children.

I think that with the airbags, it only settles about 20mm. I will try to remember to check the measurements tomorrow.

All those details are great! I'll certainly have some very useful information on hand when we go to place the tray tomorrow. Thanks once again for your help :)

When I was looking for a vehicle, asked the seller of this 130 Defender for the tray dimensions. He stated that it was 990mm off the ground (I'm surprised he doesn't have issues with clearance at that height) These are pics of his tray. I like the way the tray is mounted, leaving good storage options under the tray for use down the track (I hope this is cool to repost his images, I've hidden the rego)
https://www.aulro.com/afvb/images/imported/2012/12/836.jpg
https://www.aulro.com/afvb/images/imported/2012/12/837.jpg

[VladTepes]

iClick - as an aside - is that a "off the shelf" canopy or something you had made up? I like it.