shortening tray (aluminium)

[cavefella]

hey guys i wanna cut my tray so its kinda flush with the chassis. im always knocking it on shit it the bush, so its time for a cut.

ive searched our almighty bible and i couldnt find any threads on how to cut your tray, please help. im keen to start the cutting this weekend and im not to keen to just start hacking away with an angle grinder. please help.

im not gona cut the chassis shorter btw!!

[DUDELUX]

I have an alloy tray, it fits together like floorboards, have a good look underneath, yours might be the same.
If so, then its easy peasy.
Just unbolt the side trims, unbolt a few sections, remove and refit the side trims.
The you only have to cut the rails that hold the tray.
And done.

I cut 600mm off the back of my tray using this method.

If your tray is different, then just mark a line on the tray where you want it to end, put some tape there, and start cutting with the grinder, cut through the tape for a nice finish, put a bit of angle or something on it to make it nice and neat looking, and done.

Good luck.

[Zuri92]

i did the same way back, and as dude lux says, its like floorboards, just remove the edging on the rear, and sides, as with the sides and tailgate, then remove as many boards as required. mine were 150mm each, i took 2 out but each tray and car may vary but should be a very smilar design. mine was a triple m

[gingerbreadman]

grinding and aluminium does not go well together . the blade clogs and the aluminium melts. quicker way is to stock up on some metal blades for a jig saw...they even make them just for aluminium ..2 or 3 blades should get you across a tray if its not the floor board type and the trick with alloy is to set the jig saw to a slow speed .

[coopster]

i shorten my tray my is off a 79 model it was like floor board type then i cut the width with a 10 inch grinder slowly

[cavefella]

thanks heaps for the comments, im pretty sure mine is the floor board type. i shall look tomorrow morning. when cutting down the sides to suit, do u recommend a grinder or jigsaw, id see how itd be easier to get a straight cut with a jigsaw.

[DUDELUX]

I just used a 4inch grinder, the floorboard type alloy tray will be bolted from underneath, so its just a matter of removing the rear trim piece, loosening the side trim pieces, removing the rear section of sides, undoing the bolts underneath, lifting out the section not needed, refitting the side and rear trim pieces, then cutting any rails under the tray down.

I used the 4inch to do the tray chop on mine, but it does get some heat in it as posted.

Before you do the chop, look at the tie down rail if you have one, and make sure it will still work after the chop is done.
The tie down rail was mounted in 4 spots before I did the chop, and now its mounted in 3 after the chop.
But I also cut the front half off the rail to make way for flares/mud flaps.

[coopster]

that true with the rail my was weld not bolts and the tray was weld underneath aswell so i had to modify the hole tray but it look good now only took about 3 hours or so
good luck m8