dkyleb's Overland Build Thread

[dkyleb]

Well, since this is an overland build thread, I figured I should get a roof rack. Prices seemed insane for one pre-built, so I figure I would try building one out of 3/4 EMT and some elbows. Welding this stuff has been a real pain. My wirefeed is already set up with .045 wire, and I didn't want to buy a big spool of .025 just for this one project. So, I had some 3/32nd 6011 and gave that a go.

Got the first section done, and also grabbed some expanded metal to lay on top of it. Hopefully I can get the whole thing welded up tomorrow if weather permits.

 

[dkyleb]

I'm a terrible woodworker. I'm a metal guy, what can I say. Luckily, I've got a friend who is a talented artist, and can definitely build some stuff outta' wood! I showed him some pictures of what I was looking to do, and he sketched up the above drawing.

We took some measurements, and he went to work building this awesome sleeping platform. First thing up was the box and drawers:

We have also decided to do a hardwood inlay where the sliders mount. This will guarantee long term strength. These drawers will have a lot of weight in them, and will see a lot of abuse from wheeling. We don't want them to get a "Ikea'd"!

 

[having fun]

Dammit, you used 6011 instead of your wire feed. I used the same EMT for my rack. Running .035, pretty much use it for thin or thick metal.

Glad to see others are using the EMT for building these racks, makes it kinda easy IMO.

 

[dkyleb]

Dammit, you used 6011 instead of your wire feed. I used the same EMT for my rack. Running .035, pretty much use it for thin or thick metal.

Glad to see others are using the EMT for building these racks, makes it kinda easy IMO.

You had luck with 035? I figured it would have just pushed right through this stufff. Oh well, my wirefeed can only take the big spools anyways. Didn't feel like buying a whole big spool for this. I'm set up for TIG too, but also didn't want to run through a whole bottle of gas just to do this little project.

Yeah, I don' see the point in making it out of anything else. It's cheap and light. Shit, I could have built this thing without any welding. But I want it to be strong and sturdy since I'll actually be using it!!

 

[having fun]

I use the 10lb spools myself, but have the innershield. No burn threws, but, I weld all different size metal, so kinda used to control what I weld with it.

Besides, EMT is galvanize and takes decades to rust, other than the weld areas. I even used galvanize expanded sheets. That stuff wanted to do a nuclear melt down. I just hit the EMT and dragged into the expanded.

I'm still learning with the gas myself, just haven't gotten a comfort spot with the pressures yet.

 

[dkyleb]

I use the 10lb spools myself, but have the innershield. No burn threws, but, I weld all different size metal, so kinda used to control what I weld with it.

Besides, EMT is galvanize and takes decades to rust, other than the weld areas. I even used galvanize expanded sheets. That stuff wanted to do a nuclear melt down. I just hit the EMT and dragged into the expanded.

I'm still learning with the gas myself, just haven't gotten a comfort spot with the pressures yet.

Wow. I didn't think .035 flux-core would work with EMT! Typically, flux core wire produces more heat. I knew I should have just MIG'd this damn thing. Oh well, all 22 joints on the base are done now. Still have another 20 or so for the next portion, plus the expanded.

 

[having fun]

Wow. I didn't think .035 flux-core would work with EMT! Typically, flux core wire produces more heat. I knew I should have just MIG'd this damn thing. Oh well, all 22 joints on the base are done now. Still have another 20 or so for the next portion, plus the expanded.

That why I like using it, it's hot enough to penetrate .25". I've gotten used to when doing 16 gauge steel just turn the speed up a little and move fast.

Galvanize doesn't allow all the splatter to stick to it either. I been fabbing chain link gates this way for 30 yrs, from resi light gauge to commercial heavy.

You should play with it a little, u might learn to like it for certain projects, then again gas makes clean up a lot easier.

 

[having fun]

If I used my ac/dc stick, I would have melted mine, I use it for heavy stuff only.

 

[MN4RNR]

Great looking drawers. I am looking forward to see the finished product.

 

[dkyleb]

Great looking drawers. I am looking forward to see the finished product.

Thank you, I am too!

 

[J053619]

Build is looking good! I'm also looking into making some drawers along with a sleeping platform in the back. Can't wait to see how yours turn out

 

[dkyleb]

Installed a dashcam a few weeks ago. I went with the Mini 0805, and decided to hardwire it. I installed a dual cig lighter thing with a couple USBs. It is ignition-on powered from the cigarette lighter and has a separate, inline fuse. Works very well, and best of all, I never have to touch it.

 

[dkyleb]

Build is looking good! I'm also looking into making some drawers along with a sleeping platform in the back. Can't wait to see how yours turn out

Thanks! I'm pretty excited about it. This build is finally heading into the true overland side of things and the sleeping platform is a major step.

 

[dkyleb]

Okay, so I made some progress on the roof rack today. Most of the joints are welded, and everything else is tacked in place. I have 12 more joints left to weld up, then I'll have to clean everything up, fab up some mounting brackets then paint!

Every piece is hand coped on a bench grinder. I used a handheld pipecutter to get all of my cuts straight and square.

 

[exo_toy.]

It says Alberta under your avatar, but the Lucky lager cans are a dead giveaway. You've spent time on the island...

Nice build btw!

 

[dkyleb]

It says Alberta under your avatar, but the Lucky lager cans are a dead giveaway. You've spent time on the island...

Nice build btw!

Haha, what can I say... It's a decent beer at a good price!

I'm actually on the island right now, man.

 

[dkyleb]

After I got bored of working on the roof rack, I decided to do something I've been neglecting for a while... Fixing ANOTHER leak on my thermostat housing, cleaning my throttle body, and cleaning my MAF.

Bonus shot inside the plenum:

Everything is put back together now, just letting the gasket maker cure overnight, and I'll see how she runs in the morning.

 

[dkyleb]

Well. Took a break from my roof rack. Trying to figure out some mounting brackets, since I don't have a stock roof rack.

Anywho, decided to do a 1" body lift. This should alleviate any rubbing that I have at full flex and lock, and also give me the height+look I've been going for.

Didn't really take any other pics during install besides this one...

Aaaand all finished up:

Look's much better, in my opinion.

 

[dkyleb]

Oh, and got a couple surprises in the mail today...

Thanks [MENTION=73242]Desert Fox[/MENTION] for the BudBuilt mount!

 

[Backwoods Rambler]

I'm curious how the alignment of the hidden which mount will change with the body lift