[bobs409]

I’ve been fabricating the new top rail that goes around the box. Here in the first photo, you can see the one side is just about done. It is sitting upside down but you get the idea. It’s made of a piece of 1-1/2 X 1-1/2 angle welded to a piece of 2 X 2 inch angle that has had ½ inch removed from one side. This gives me a finished rail that measures 3-1/2 across the top with 1-1/2 inch sides.

I’ve looked into many ways to make this part but this way worked out the best and most economical. Although it’s time consuming as you have to cut off some metal lengthwise on the 2 X 2 and then weld the entire length, it gives me the exact dimensions the original piece was. I imagine the original might have been made in a large press or similar but that’s not an option I have. When all installed, you’ll never know the difference.

Shown in photo #2, I have the new rear panel clamped in place for a test fit. Looks pretty good, just a little smoothing of the edges and it will be ready to weld in. Behind it I made new brackets shown in pic #3 that bolts the C channel of the box to the truck frame. These brackets are installed with grade 8 ½ inch bolts. Even though it won’t be towing any cars, it will be built strong so it could do so at anytime!

So finally, one pair of top rails are done! (last pic) You better like welding if you’re going to make these!