Custom built dual cab steel tray

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Rip it up
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Custom built dual cab steel tray

Unread post by Rip it up » July 9th, 2013, 8:41 pm

Hello everyone,

I had a small amount of panel damage on my wildtrak during my last outing. Broken taillight. A caved in dint that won't pop out with magnets or suction.

So instead of going down the insurance option I want to build a steel tray. I do have a TJM canopy on the back that did not get damaged. This will be sold separately.

I have searched the forums for a ranger with a custom steel tray but did not find any. I did find a few hilux dual cabs with a style I like.
image.jpg
Has anybody got some helpful hints to get me started designing and building my new tray.
Materials to use. Dimensions. Options to include.

My other modification I want look into is a raised towbar. I need more ground clearance. Do I need an engineer to design the new towbar? Or Is there an off the shelf option? Basically I want it to be level with the chassis rails.

Thanks Damo.
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Last edited by Rip it up on June 14th, 2015, 12:22 am, edited 1 time in total.
2009 Ford Ranger Wildtrak.
Built not bought.

fred99999au
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Joined: July 20th, 2008, 12:23 pm

Re: Any advice/help designing Custom built dual cab steel tr

Unread post by fred99999au » July 11th, 2013, 8:36 am

search for Tazzie. he had a PJ with a steel tray like what you are looking at. Twas in a car yard down the road for a while.

Rip it up
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Re: Any advice/help designing Custom built dual cab steel tr

Unread post by Rip it up » July 15th, 2013, 5:08 pm

So like my searching shows no modified trays getting around on a ranger. Hmm. Time for autocad designs I think.

Basically want it level with towbar tongue. Flat checker plate at a height suitable to original wheel arches.
Use the space under tray to put water tank, recovery gear tray, wedge shaped storage in the rears. And a lockable marine style fuel cap flush on the checker plate.

Watch this space for designs.
2009 Ford Ranger Wildtrak.
Built not bought.

fred99999au
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Posts: 767
Joined: July 20th, 2008, 12:23 pm

Re: Any advice/help designing Custom built dual cab steel tr

Unread post by fred99999au » July 17th, 2013, 10:59 pm


Rip it up
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Re: Any advice/help designing Custom built dual cab steel tr

Unread post by Rip it up » August 3rd, 2014, 12:34 am

So I thought it would be about time to progress my designs further for the next project.

I have been looking at what features I need to incorporate with my tray build.

A few ideas.
Used as a camping rig. Basically carts fridge, space box, chainsaw, canvas tent and poles, self inflating mattress, chairs, tables etc.
Occasionally takes two med/large dogs up the beach.
Tow various boats regularly. It's main use.

I willbe keeping the size to a minimum as I don't want a huge rear overhang or side vision disrupted (for towing). So the edges will stop at the body junction. Like the tub doe already. Guards will be flared out to suit the tyre overhang. Rear length will stop at the tow ball socket. Same as the tub step.

Drop sides won't be needed as all my equipment gets tied down when travelling.

A removable dog crate/lockable area will be made to match the head board profile. This will stay on most of the time. Twin door with a portion on the drivers side to take the fridge dimensions.

Rear corner storage boxes tapered to the tail. Simple recovery storage area. Probably be built from aluminium. Lockable.

Extra fuel is a big issue. 2 options will be looked at. A head board vertical tank. 100mm wide and built as the head board. Permanent instalment. Second option is a poly tank bracketed to sit above the original tank. Aiming for 70L extra.

I'm leaning towards a hardwood deck on the tray. Mainly for the visual effect. But also I hate the rust factor of steel checkerplate. And the tinny noise factor of aluminium.

So I have done a little photoshop effect of what I'm looking at minus the dog crate.
image.jpg
Now to design it to scale and order materials.
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2009 Ford Ranger Wildtrak.
Built not bought.

Ranger Stretch
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Posts: 479
Joined: September 28th, 2012, 1:10 pm

Re: Any advice/help designing Custom built dual cab steel tr

Unread post by Ranger Stretch » August 4th, 2014, 7:37 am

Hi Ripit.

Almost finished mine. Have a look at my thread (in my signature below). Mines full size 6x6ft. If ya need tips pm me.

Cheers
Mods in order of completion.
Custom Rear Carry Bar, Duel Battery System, Double Din GPS Headunit, Bullbar, 100w HID Driving Lights, 265/70/16AT's and Sunnies, Hitch Receiver in Bullbar for Winch, 13000lb Winch, Anderson Plugs Front and Rear for Winch. My tray build thread viewtopic.php?f=118&t=151073

Rip it up
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Re: Any advice/help designing Custom built dual cab steel tr

Unread post by Rip it up » June 11th, 2015, 7:21 pm

Hey guys. It may have taken a year it I have finally started work on building my tray.

I spent some time measuring and designing a tray that incorporated everything I wanted.

No side boards.
No side or rear overhang.
Tie down rails up on top.
Toolbox in the floor for recovery gear. Lockable
AUX fuel tank under the front section.
Stupid strong. Steel construction. Built by myself.
image.jpg
First task was to remove the tub.
image.jpg
image.jpg
Do with that out of the way the construction started.
The materials used are:
100 x 50 x 3mm RHS.
40 x 40 x 3mm SHS.
40nb standard weight pipe.
25nb 316 stainless pipe. Tie down.

The external dimension of the frame are 1690mm wide to finish neat on the cab of the ute.
And 1700mm long to finish flush with the towbar receiver tube.
I've got 250mm height from tray floor to the chassis rail. To allow room for the tank and toolbox to miss the spare tyre winch area.
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2009 Ford Ranger Wildtrak.
Built not bought.

Rip it up
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Posts: 67
Joined: July 10th, 2012, 1:33 am

Re: Any advice/help designing Custom built dual cab steel tr

Unread post by Rip it up » June 11th, 2015, 7:42 pm

So the basic frame was easy enough. Having dimensions already calculated by auto cad made the cutting list easy to work out.
image.jpg
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The next mission task sounded easy enough on paper but turned out to be a massive job. But the effect and protection will be worth it.
image.jpg
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These will get a plate mounted to protect from flying stones off the Tyres.

I turned my attention to the headboard shape after the lights were organized. This headboard needed to hug tightly to the cab. I also need to leave access to my roof rack mounted solar panel.
image.jpg

112 degrees was the magic angle for needing it in the future. Or 68 degrees across the faces of the cutdown 90degree elbows.
With a few shallow bends on the pipe it now tucks in nice and tight.

And that's were I am at the moment. 4 days part time work so far. Still lots to go.
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2009 Ford Ranger Wildtrak.
Built not bought.

Rip it up
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Posts: 67
Joined: July 10th, 2012, 1:33 am

Re: Any advice/help designing Custom built dual cab steel tr

Unread post by Rip it up » June 11th, 2015, 7:43 pm

image.jpg
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2009 Ford Ranger Wildtrak.
Built not bought.

Rip it up
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Re: Custom built dual cab steel tray

Unread post by Rip it up » June 22nd, 2015, 8:22 pm

Just another photo update.

General fabrication work still ongoing.
image.jpg
image.jpg
Mudguards mock up positioning.
image.jpg
Head board detail.
image.jpg
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2009 Ford Ranger Wildtrak.
Built not bought.

smikED
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Re: Custom built dual cab steel tray

Unread post by smikED » June 23rd, 2015, 7:36 am

Love it! Keep the updates coming.
Can't say I've seen many of these trucks with a shortened steel tray.
DAILY: 2008 PJ XL 4x4, 15x8 -26 sunnies, 31x10.5 Hankook MT, Diff breathers, Tub liner, Aftermarket intercooler, Twin light bars
WEEKEND: 1994 ED Falcon, Full options, V8, leather, gilmer
NEVER ENDING: 1966 Chev Impala, Gen3, powerglide

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Re: Custom built dual cab steel tray

Unread post by Rip it up » June 23rd, 2015, 3:52 pm

Cheers smiked.

I wouldn't call it that short at 1700. Finishes flush with the towbar tongue. Just looks short I guess. Hate smashing hands and trailers when hooking them up. And I'm conscious about weight over the rear axle.


Little job completed this morning.
Stone guard for the rear tail light wiring.
[attachment=0]image.jpg[/attachment]
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2009 Ford Ranger Wildtrak.
Built not bought.

Rip it up
Here and there
Posts: 67
Joined: July 10th, 2012, 1:33 am

Re: Custom built dual cab steel tray

Unread post by Rip it up » July 7th, 2015, 11:28 pm

So a much needed update is required.

Currently the tray is in the final stages for construction. Finishing off the little details before welding out the floor sheet.

Tie down rails were TIG welded into place.

Stainless toolbox fully seam welded and a water channel added to the opening.
image.jpg
Headboard panel added and cross tube. Still needs the diagonal supporting tubes added.
image.jpg
Drivers mudguard fitted, requires a few strategic brackets to give the guard rigidity and cut away the points which will fowl on the body mounts.
image.jpg
About 12hrs of fabrications required to finish off the tray.
Consisting of:
Passenger mudguard
Toolbox lid and hinges. Lock point etc.
head board piping.
Seam weld the checkerplate.
Drill and tap the stone guard bolts.
Rubber mudflaps.
Breather bracket behind the head board plate.

Thanks for looking.

Damo.
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2009 Ford Ranger Wildtrak.
Built not bought.

Ian Reichelt
I'm new, be nice!
Posts: 1
Joined: June 29th, 2015, 12:18 am

Re: Custom built dual cab steel tray

Unread post by Ian Reichelt » June 27th, 2017, 9:19 pm

Just wondering how much it cost to build the tray? because i'm looking into building a tray similar this for my 08 PJ Ranger.

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