Things You'll Need:
- Pickup truck
- Welder
- Steel square tubing
- Steel sheet metal or wood planks for flat bed floor
- General hand tools
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Step 1
With the vehicle on level solid ground, block the wheels, and disconnect the negative battery cable. Next, remove the tail lights and disconnect the wiring, disconnect the fuel filler neck from the truck bed, and remove the tail gate.
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Step 2
Remove the bolts holding the truck bed to the frame, typically 8 bolts, but can be more or less depending on the size bed and model truck.
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Step 3
Remove the rear bumper, and inspect the under side of the bed for wires, linkages, and anything that may be connected to the bed.
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Step 4
With the bed unbolted, and no longer held on by any wires, using a hoist, or for most of us, three or four friends, remove the truck bed carefully and set aside. Inspect the frame of the truck now for rust. Also inspect the wiring and brake likes, as this is the perfect time to replace any of these things if need be.
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Step 5
With the bed off, you can measure the old bed, or, if you want the flat bed larger or smaller, calculate your own measurements. Now that the bed measurements are done, measure and cut four pieces of square tubing to make the perimeter of the flat bed. 2" steel square tubing is a good place to start, you can go bigger and thicker if you plan on a lot of weight going on the bed.
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Step 6
Place the four pieces of tubing together, and weld. When the metal has cooled from welding, place the perimeter frame on the truck. Measure across the frame and cut cross braces, typically four braces.
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Step 7
Line up the cross brace pieces over the bed to frame mount locations. with the braces lined up, tack weld them, being careful to cover the fuel tank with an approved welding blanket. Remove the frame and finish the welds on the cross braces.
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Step 8
Place the frame back on the truck, and mark where to drill for the mounting bolts, also mark where the gas filler neck is to the frame. Drill out the marks for the bolts large enough to fit a nut that fits the bed mounting bolts. Then, weld the nut flush inside the frame, so the bolt has something to screw into when mounting the bed. Make a plate with a hole large enough to fit the gas filler neck through, and rivet, bolt, or weld it to the frame.
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Step 9
The flat bed is almost complete, any optional bracing should be done now, though the frame is structurally sturdy as it is, some may want extra strength if planning on large loads. With all the bracing done, it's time to choose the bed floor. Sheet metal can be used, either steel or thick aluminum, steel or aluminum diamond plate, or wood. It's up to the builder on what to use. Measure and cut to fit the bed, then rivet, bolt or weld the floor the flat bed frame. Using bolts and multiple panels makes it easier to remove the bed floor panels for repairs to the vehicle with out removing the frame. If using wood, angle iron steel may be a better option for the perimeter frame so the wood lies flush in the frame.
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Step 10
The flat bed is complete, just bolt it to the truck frame, making sure to connect any ground wires the may have been held down by the bed bolts. Install the bumper. Purchase DOT truck lights and bolt to the bed frame, and wire the lights. Install the gas filler neck. Reconnect negative battery cable and test lights.
Comments
shasha10 said
on 6/11/2009 Very involved process on how to make a custom flatbed and you did a great job with the instructions. I like step 10 when it is all done.