Outer Limits 4x4 Board

I'm starting this thread because I coudln't find a useful thread dedicated to making a dual cab GQ. I'll add more photos and info as the build progresses.

Here's some picts of my GQ which I started chopping today.



This is how the truck looked when I started to strip it.


The marks from the tyre rubbing the inner gaurd. I'm hoping for more wheel travel once the body is removed.


I 'hacked' the roof off in the morning and trimmed it properly later on.


This is the rear roof section that I will be using at the rear of the cab because my current one is damaged and rusty.



The rear of the cab trimmed and fitted, it just needs to be welded in place. The rest of the body will be chopped off next.



The D pillars at the rear of the wagon is slightly narrower than the C pillars. This will be adjusted as the build goes on.

It's a weekend-only project so it may take some time to fully complete. Feel free to ask any qeustions.

Lookin good so far mate.

gday , looking good so far , i found the members section pretty good for hints and info
keep the pics coming , dual cabs are great cos they are all unique in some way !
cheers
daz

Here's some picts of Sunday's effort.


I used a string line to help keep my lines straight.


The frame for the rear wall tacked in place. I used some 3mm plate bent at 110-degrees as the base of the window frame.

More picts next weekend...

hows the cut coming along?

Here's some picts from yesterday and saturday.







I've nearly finished the welding, all that's left is around the mud gaurds and under the floor -the bits I'm not looking forward to because I hate welding upside-down.
I'm hoping to have it ready for paint by the end of this comming weekend -the long weekend, so it should be ready...hopefully...

Hey mate awesome progress, I agree with your sig a dual cab is a real mans quarter chop. What are you gonna use for the rear window? It is starting to look the part now, I used the 60 series rear window in my red one just about to use an 80 series window for my new one. Keep up the good work and progress shot, as this will inspire me to finish mine and to extra cab truggy set up for my first one
Cheers for the inspiration keep it up

Should have kept it a well back! looks good though. Will be cutting mine up when I have the funds!!

unmass wrote:What are you gonna use for the rear window?

I'll see how much it will cost to get a window cut to suit the rear of the cab. If it's gonna cost too much, I'll make a window from UV resistant polycarbonate sheet.

I like how all these are similar..but different especially the way rear walls are made and the variations in rear windows..I just went for the single cab rear wall..both times..nice work

patrol_maverick wrote:

unmass wrote:What are you gonna use for the rear window?

I'll see how much it will cost to get a window cut to suit the rear of the cab. If it's gonna cost too much, I'll make a window from UV resistant polycarbonate sheet.

Polycararbonate sheeting is not street legal in motor vechiles from memory.
When i had 4x4s or cars engineered they checked that it was all glass. It is a safety point, incse you are in a accident and they need to smash the back window and it is poly they cant and the time difference in a worse cas senareo could mean life and death.

This is why you have to report to police and fire brigade if you use lexen sheeting in your windows of your house instead of glass (it is a safety thing)

Mark.

MARKx4 wrote: Polycararbonate sheeting is not street legal in motor vechiles from memory.
When i had 4x4s or cars engineered they checked that it was all glass. It is a safety point, incse you are in a accident and they need to smash the back window and it is poly they cant and the time difference in a worse cas senareo could mean life and death.

Good point, I'll check into that. I went to the engineers this arvo to get a few answers to some other questions I had. I think I'll pass easily, they passed one not long ago and mine is fairly similar.

Nice looking chop so far mate

patrol_maverick wrote:

MARKx4 wrote: Polycararbonate sheeting is not street legal in motor vechiles from memory.
When i had 4x4s or cars engineered they checked that it was all glass. It is a safety point, incse you are in a accident and they need to smash the back window and it is poly they cant and the time difference in a worse cas senareo could mean life and death.

Good point, I'll check into that. I went to the engineers this arvo to get a few answers to some other questions I had. I think I'll pass easily, they passed one not long ago and mine is fairly similar.

Where are you at and which engineer are you using? Reason I ask is mine was done not long ago and your is fairly similar to mine.

mattsluxtruck wrote: Where are you at and which engineer are you using?

I'm using Collins & Associates Engineers in Taree.

Here's some picts from the long weekend.
The body is basically ready to be bogged and sprayed, so that will hopefully get done soon.
I also moved the towbar and fuel tank. I was going to wait until after I fitted a tray, but I ended up doing it this weekend while I had time. The towbar sits above the chassis now, and the fuel tank also sits 100mm higher for extra clearance. The fuel tank has to be mounted backwards in order to fit but only the fuel tank under-tray needs to be modified slightly. I made some brackets for the tank to bolt to, and mounting the towbar only required 6 holes to be drilled in the chassis top. I also removed the tie down points from under the chassis.

Looks good.
I kept mine as a well back.
Bestthing I ever did to it. Makes the trucked so much more practicle.
Bogged would never approve but it is a worthwhile change.

Here's another update. I got my truck back from getting painted about a week ago so here is some picts.

Nice work mate! Looking good

wow nice work mate wish my extra cab looked that good

That looks awesome buddy,wish i spent the time gettin my bog as smooth as yours. Glass window looks tops, any chance of a rough price on the custom window, looks better then my polycarb job!

joneso wrote: Glass window looks tops, any chance of a rough price on the custom window, looks better then my polycarb job!

The rear window cost $280 cut & fitted from Windscreens O'Brien. It's made from tinted laminated glass. They even marked it to say complies with Australian standards. I reckon it was money well spent.

Thats a tidy chop mate i like it

I've finally installed some tail lights which only took 2 months and 2 sets of lights before I got the right ones.
I've also added some body support mounts to stop the rear of the cab from bouncing.

Hey there ... nice job!

Mind if I ask what size RHS (incl thickness) and sheet you used?

Any chance of a pic showing the rear seat in place (perhaps with one half folded down)? Will help me decide where to chop mine.

I really appreciate you taking the time to post the pics of your chop ... a great resource for the rest of us!

Cheers, Stealth.

awesome work mate. bit over half way through doing mine at the moment.

did you're engineer reccomend the extra body mounts? seems lIke a good idea

Calvin

hokey wrote:did you're engineer reccomend the extra body mounts? seems lIke a good idea

He didn't recommend them, I just noticed in the mirror how much the cab bounces so I fitted them. I still haven't got around to getting the certificate but I'm sure he'll be fine with them.

stealth fighter wrote:Hey there ... nice job!

Mind if I ask what size RHS (incl thickness) and sheet you used?

Any chance of a pic showing the rear seat in place (perhaps with one half folded down)? Will help me decide where to chop mine.

I really appreciate you taking the time to post the pics of your chop ... a great resource for the rest of us!

Cheers, Stealth.

The RHS is about 50x25 and the sheet is 1.6 I think- I just asked for body sheet. I'd go for 2 or 2.5mm next time because the body sheet buckled a bit where it's welded to the frame. The angled piece under the window is 3mm flat bent at 120 degrees.

Here's some photos from the other week. The seats will fit but the headrests won't. Having the pillars look neat and not bulky was more important than the headrests. The fridge and recovery gear tub normally replaces the seats anyway, but if I ever need the seats with head rests I'll just make some brackets that hold the headrests parallel with the window.





I think posting up the picts might have been a bad idea. I think it's lead to alot of unhappy wives and girlfriends

Some interior picts as requested from PM;

-The first pict shows the framework which will be covered once I finish the board I'm making for it. Also you can see the grey plastic seatbelt cover trim which has been shortened to fit.

-The second pict shows how the roof lining was finished off with aluminium flat bar and button head self-drillers, both painted grey. I'll fit a dome light above the window one day. Tip: Fit the roof lining before the window!!

The project's comming along slowly now that the house reno's have started.