Anyone tried to increase the height of their tray Drop Sides?

jvb
Here and there
Posts: 39
Joined: February 8th, 2013, 7:56 am

Anyone tried to increase the height of their tray Drop Sides?

Unread post by jvb » June 21st, 2018, 10:39 am

Has anyone increased the height of their aluminium drop sides and tail gate?
Mine are 250mm and I have a 300mm high toolbox which I would like to sit below the drop side.
Could you add a 50mm aluminium extrusion to the top of the sides and tail gate?
Cheers.
2014 BMW X3
2004 PH Courier 2.5TD
1973 T140V Bonneville
1954 Zündapp 250 Elastic

hoyks
Avid Poster
Posts: 723
Joined: April 13th, 2003, 9:19 pm
Location: Marburg, QLD

Re: Anyone tried to increase the height of their tray Drop Sides?

Unread post by hoyks » June 22nd, 2018, 4:49 pm

You could easily enough. Drop down to the aluminium supplier and get some 50 x 20mm rectangular extrusion or a profile that works for you as there might be something better suited off the shelf.

It might be a bit inconvenient in that the getting rivets in to hold the extensions on might be an issue. Rectangular Hollow section means you can't get rivets in from the extension side. On the drop sides on my ute, even getting access from the underside is a bit hard. It is an upside down U around the top edge, but even with specialist riveting tool armed with a 90 degree head, getting a rivet in is a bit tight. 90 degree heads aren't cheap either.

The other thing is that a single line of rivets up the middle is not the best option as any loading that wiggles side to side will make the rivets work loose.

For a reasonably strong and neat when viewed from the outside, you'd be better sticking the extension onto the top of the existing side with a strip of double sided tape and fitting a strap covering the gap on either side with rivets into the drop side and the extension. If you didn't want the strap on the outside, then rivets up from the bottom and a strap on the inside.

jvb
Here and there
Posts: 39
Joined: February 8th, 2013, 7:56 am

Re: Anyone tried to increase the height of their tray Drop Sides?

Unread post by jvb » June 22nd, 2018, 5:45 pm

Thanks. I'll have a look at what size extrusions are available. I was thinking rectangular hollow myself or a channel.
I can press in nutserts or self clinching nuts or studs, but will have to see what's available. I will give it a go and post an update here.
2014 BMW X3
2004 PH Courier 2.5TD
1973 T140V Bonneville
1954 Zündapp 250 Elastic

jvb
Here and there
Posts: 39
Joined: February 8th, 2013, 7:56 am

Re: Anyone tried to increase the height of their tray Drop Sides?

Unread post by jvb » July 29th, 2018, 12:00 pm

OK, worked out really well using aluminium extrusions, RHS, 76.2x 25.4 x 2.4mm.
I used M8 rivet nuts in the extrusion and screw them to the top of the drop sides with s/s M8 cap screws. Looks great.
Total height is now over 300mm and I can fit a tonneau cover over my toolbox.
Will post photos later.
2014 BMW X3
2004 PH Courier 2.5TD
1973 T140V Bonneville
1954 Zündapp 250 Elastic

jvb
Here and there
Posts: 39
Joined: February 8th, 2013, 7:56 am

Re: Anyone tried to increase the height of their tray Drop Sides?

Unread post by jvb » July 30th, 2018, 6:11 pm

jvb wrote:
July 29th, 2018, 12:00 pm
OK, worked out really well using aluminium extrusions, RHS, 76.2x 25.4 x 2.4mm.
I used M8 rivet nuts in the extrusion and screw them to the top of the drop sides with s/s M8 cap screws. Looks great.
Total height is now over 300mm and I can fit a tonneau cover over my toolbox.
Will post photos later.
M8RivetNut.jpg
M8 rivet nut. Once in, hard to remove.
20180730_164548.jpg
You do not have the required permissions to view the files attached to this post.
2014 BMW X3
2004 PH Courier 2.5TD
1973 T140V Bonneville
1954 Zündapp 250 Elastic

jvb
Here and there
Posts: 39
Joined: February 8th, 2013, 7:56 am

Re: Anyone tried to increase the height of their tray Drop Sides?

Unread post by jvb » August 15th, 2018, 4:53 pm

Looks even better with the tonneau cover fitted.

Image
2014 BMW X3
2004 PH Courier 2.5TD
1973 T140V Bonneville
1954 Zündapp 250 Elastic

Return to “Body and Barwork”