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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #50 on: October 11, 2014, 12:22:49 PM »
I learned to temporarily hold everything in place with zip ties
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #51 on: October 11, 2014, 12:23:20 PM »
I used two layers of electrical shrink tubing at the T-Clamp points to totally eliminate any chafing
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #52 on: October 11, 2014, 12:24:07 PM »
All the lines and clamps are now installed, and this part of the oil cooler relocation is in the bag
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #53 on: October 11, 2014, 12:24:49 PM »
Next up I needed to cut in an access from above for the new battery and auxiliary electrical compartment
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #54 on: October 11, 2014, 12:25:45 PM »
It will go in here
The actual opening will be 8.5" X 21"
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #55 on: October 11, 2014, 12:26:39 PM »
That new sheet metal saw proved to be a useless piece of junk, so I finished the job with a cut off wheel
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #56 on: October 11, 2014, 12:27:24 PM »
The concept will be to have a flange with welded on nuts serving as a nut plate which will serve as the base mount for the top plate which is cut from 11 gage plate
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #57 on: October 11, 2014, 12:28:38 PM »
Here are the parts liberated with a plasma torch from that ugly plain old plate of steel!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #59 on: October 11, 2014, 12:30:36 PM »
Might have been useful to sneak in Mexicans, the skinny ones at least, had it not been for that battery and things under that hole! JR, don't get any ideas!

You know what they say, if the bottom plate fits, then the top is sure to fit as well!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #60 on: October 11, 2014, 12:31:49 PM »
So that's it, the finish of another build day
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #61 on: October 11, 2014, 12:33:41 PM »
With the goal of being to drop that bed back on this week still in sight, I pushed ahead and got the access panel completed along with some other stuff.

I started off with spraying the snorkel and the gas port panels with the bed coating. Instead of using the usual Duplicolor stuff, I switched to a rustoleum product. It is OK but the duplicolor stuff is better I think

It looks like it had a run or two, but I top coated it later and most of that went away
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #62 on: October 11, 2014, 12:34:38 PM »

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Join Date: Oct 2011
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Posts: 10,336  Starting with the underside flange clamped in place, one by one, I drilled 1/8" pilot holes

Not because I'm a pilot and I'm drilling holes you bonehead...But because they're called pilot holes...kids... 
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #63 on: October 11, 2014, 12:35:16 PM »
I like using the clecos because they hold everything together very tightly thereby ensuring the holes all line up and stay that way

So as I went along I snapped in another of those little gems until all the holes were in
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #64 on: October 11, 2014, 12:35:59 PM »
Four of those holes will remain 1/8" and be used to pop rivet the nut plate into place to sort of hang it there. It will be held in place, of course through the clamping force of all those 5/16" screws

With the holes drilled, I transferred the nut plate onto the lid and using it as a template, drilled through the top plate
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #65 on: October 11, 2014, 12:38:13 PM »
Here's the access cleaned up
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #66 on: October 11, 2014, 12:39:22 PM »
To make the thing a nut plate, I needed to add some nuts, don't you think? Best way to do that is to first add some bolts.

With the thing securely bolted together, the nuts were welded to the lower plate
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #67 on: October 11, 2014, 12:40:51 PM »
Then the almost completed nut plate was treated to acid etching primer
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #68 on: October 11, 2014, 12:41:28 PM »
Since I might be stepping around this thing, I decided to flush mount the hardware.

I'll be using these allen-headed stainless screws
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #69 on: October 11, 2014, 12:42:46 PM »
Counter sinking them was a simple matter of drilling out the bevel with a large drill bit, then setting the plunge depth and repeating over all the holes
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #70 on: October 11, 2014, 12:43:56 PM »
The various parts got a few coats of primers of varying types and a coat of bed liner for the bottom side of the access panel
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #71 on: October 11, 2014, 12:44:35 PM »
The opening was primed as well
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #72 on: October 11, 2014, 12:45:48 PM »
Time to permanently rivet in the nut plate
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #73 on: October 11, 2014, 12:47:02 PM »
A quick check of the top for proper fit and I think this one is ready for sanding and bed liner!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #74 on: October 11, 2014, 12:47:41 PM »
It looks good from the underside as well
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #75 on: October 11, 2014, 12:48:29 PM »
The fuel filler plates are now finished and ready to install
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #76 on: October 11, 2014, 12:49:23 PM »
Quote:
Originally Posted by EL TATE View Post
^^x2. rubberized gasket material that forms to the bed possibly? could seal from the bottom but that would hold water against the metal...

But then again, I haven't seen "END OF BUILD DAY XXX" posted yet so maybe we're jumping the gun.


Yea, you're jumping the gun

The truck is getting a topper...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #77 on: October 11, 2014, 12:50:45 PM »
Man, getting this thing ready for the bed liner spray is a lot of work (Again)

I had a goal of setting the bed back onto the chassis tomorrow, but after an entire day of sanding, taping, and some other things I am almost completely taped up, but only about 40% sanded at the most.
It is easily going to span into tomorrow afternoon to get the areas sprayed with the bed liner.

I wanted to get some of the parts off the floor so I bolted on the snorkel

I used some good stainless hardware with a lock washer and a large fender washer to conform to the inside of the tube
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #78 on: October 11, 2014, 12:51:30 PM »
It fit up like it was made for the truck
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #79 on: October 11, 2014, 12:52:35 PM »
The brown truck finally delivered the hydro-boost brake fittings, so, before the dog got to them, I thought I'd stick them in the bores
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #80 on: October 11, 2014, 12:53:18 PM »
Those fittings will allow me to use aircraft lines or tractor hoses made up locally. That stuff will be far superior to factory pressure hoses and easy to replace, just find a tractor and harvest the line you need!

I messed with the fuel filler panels because I was not happy with how that crappy Rustoleum bead coating turned out. I'll stick them on in a couple days
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #81 on: October 11, 2014, 12:54:47 PM »
THe endless taping and sanding is mind numbing. Despite KLOVE playing in the background, I just pushed through...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #83 on: October 12, 2014, 09:00:04 PM »
And sanding again...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #84 on: October 12, 2014, 09:01:31 PM »
Well, got the thing sprayed finally

The day started with more sanding and masking things up
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #85 on: October 12, 2014, 09:02:40 PM »
I used a lot of paper and masking tape!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #86 on: October 12, 2014, 09:03:28 PM »
The gun used to spray something that thick splatters the stuff all over and with some force. That means the blobs of the liner that missed will easily travel some distance and hit things you care about. So covering everything is the order of the day with spraying bed liner type coatings.
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #87 on: October 12, 2014, 09:04:00 PM »
The tailgate was flipped over and got sanded and prepped for some more primer and the bed liner
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #88 on: October 12, 2014, 09:04:54 PM »
After washing everything with a good solvent cleaner, I shot a coat of primer/sealer over the bed
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #89 on: October 12, 2014, 09:05:44 PM »
I tested the U-Pol Urethane two part bed liner on the tail gate first
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #90 on: October 12, 2014, 09:06:28 PM »
That turned out OK, so onward to the actual bed

I shot a flat area and part of the side to experiment
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #91 on: October 12, 2014, 09:07:01 PM »
After a second coat on the tailgate
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #92 on: October 12, 2014, 09:08:05 PM »
Next up is the door sill areas that is a high wear part of the cab to be sure
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #93 on: October 12, 2014, 09:09:00 PM »
All that was working out well, so on to the roof
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #94 on: October 12, 2014, 09:10:17 PM »
It definitely looks pretty rough up there, but I had some reasons for doing it that way.
First where you hook a foot under the roof rack when climbing up there it should provide some purchase.
Secondly, it will definitely not be reflective.
finally, a roof that coarse will hold onto dust which causing some good natural streaking and natural camouflage. All you have to do is drive it around and all the dust and pollen gets caught up and when hit with morning dew, starts to mute out everything.
Mostly, I really don't care much about how it looks, but over all I'll give the roof a:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #97 on: October 12, 2014, 09:16:29 PM »
I used 7 liters of the urethane
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #98 on: October 12, 2014, 09:17:06 PM »
One left from that rather expensive case
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #99 on: October 12, 2014, 09:17:43 PM »
You may recall back at the beginning of the winter, I had sprayed the underside of the bed with a two part Epoxy bedliner.
THis application used a two part Urethane.

Hands down the Urethane is the better product. When I sanded up the Epoxy, it scratched easily. Sanding the Urethane is like pulling ticks from a coon dog...You only create vacancies for new ticks... What the Warrant Officer was trying to say is the Urethane is difficult to scratch as in scratch resistant!
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