Truck sides build

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Im a wanna be welder.  My real job is caring for trees.  Ive been wanting an aluminum chipper body for years.  I bought a syncro wave 250 last year and have been practicing ever since.  I was ready for this project i felt.All material is .125 or .130 6061 mostly.  The side panels are .190 and will use a special 3m adhesive to prevent warping if welded.  The top is removable.  Heres the progress so far.For some reason the iPad posts these upside down. Attached Images
Reply:One more Attached Images
Reply:Everything is tacked in the pictures.Johnt, will probably get in touch with you this weekend.  Will start final welding then!
Reply:where do you live, Oz? Flip the pics man!There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:All the blood runs to my head, but it looks great! I've been surprised how little distortion I get welding aluminum.
Reply:I cant flip them on this ipad, im sorry!
Reply:These were moving like crazy.  My bro came over and we devised a plan to use multiple clamps, its within 1/16 square, it is what it is.
Reply:Is it just easier to weld them upside down? I bet it helps to keep welding spatter off the paint.
Reply:He is just bragging about how well welds hold, Even upside down.
Reply:Originally Posted by brendonvJohnt, will probably get in touch with you this weekend.  Will start final welding then!
Reply:BrendonDid you preheat at all?Looks like yer working outside...Its been colder than a witches broomstickMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:No, im inside, have a stove in the garage.  Brought outside for fitup.
Reply:Looking good..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Im looking for advice.  You can see how the bottom sides,will be three pieces.  Two 48" sides, and a 6" connector over the headboard.  The back will have a hinged tailgate, and a removable spreader,bar.Do you think i should connect the front over the heade board via welding, or keep it bolted and three pieces.  I have a log picker to lift it off, so thats not an issue.  Im thinkng if i weld it, even with temporary braces, the torque on that top section from te side panels flexing in will be enormous.   I thought i wanted it one piece but im really stuck here...
Reply:Oh,  i ill have triangle gussets in front btw.
Reply:Going with fully welded btw.Some progress.  Working on it during the week currently, weekend been to busy. Attached Images
Reply:That will never hold that will never work that will just break apart you are wasting your time..Sound familiar?I like it!So far so good but if I were you I would extend the front of the rear fenders as low as the box straight down..But that's just me.Nice truck!...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by brendonvIm looking for advice.  You can see how the bottom sides,will be three pieces.  Two 48" sides, and a 6" connector over the headboard.  The back will have a hinged tailgate, and a removable spreader,bar.Do you think i should connect the front over the heade board via welding, or keep it bolted and three pieces.  I have a log picker to lift it off, so thats not an issue.  Im thinkng if i weld it, even with temporary braces, the torque on that top section from te side panels flexing in will be enormous.   I thought i wanted it one piece but im really stuck here...
Reply:Don't forget drain holes in the bottom of all your tubes. You are clearly in a freezing area and those tubes will get water in them even fully welded. What are the sides going to be? I've never built a chipper box, but I've fixed a bunch. They sure seem to take a beating.
Reply:looks like you studied aluminum welding. awesome work!bosses stuff:trailblazer 325maxstar 200my stuff:sa 200fronius transpocket 180100 amp Lincoln w/f97 f350 DITKevin
Reply:Thanks guys.The sides are .190 alum sheet.  Im owner operated so everything stays nice and pretty.
Reply:Zap.  The truck is a fair weather truck.  Doesnt see snow, and only if we get stuck in the rain.  No plow, stored under cover.  I am however more than likely going to put a larger toolbox there, like the other side has.  Not enough storage as is.Welderj, you have me thinking about bolting now.  I really dont want it to tear apart when it gets lifted.  That top piece is 6"x2"x.125.  Not much weld area holding two sides together.  Think i just thougt of a slick way to do it.  Thanks for the advice!Ive got the other materials being delivered friday.  Hope to wrap this up on about a week.
Reply:What are you going to use for the roof?
Reply:Alum on the sides and front.  Thinking thin ply or platic sheeting from farmtek on the very top.The whole top is removable.Pic in post 10.Last edited by brendonv; 03-13-2014 at 08:54 AM.
Reply:One side panel sheet cut and mocked up.  Pondering how much adhesive and how and where to weld in case i ever need replacement. Attached ImagesOriginally Posted by brendonvOne side panel sheet cut and mocked up.  Pondering how much adhesive and how and where to weld in case i ever need replacement.
Reply:The problem with that much weld will be replacement if need be will be a heck of a job.Im currently thinking three ss bolts on each of the four vertical uprights.  The rest will use 3m 560.  The rep brought some over last week, after cured i could not separate the tubing off a test panel with a sledge hammer.  I cant imagine having ti replace but you never know.  My old box was .125 and had three dents over three years.  This new truck wont haul any wood either.
Reply:Side mounted with the adhesive.  Worked awesome.  Working on wrapping up this week.  Have the roof extension all tacked, will final weld that after work this week.  Tailgate done and mounted too. Attached ImagesLast edited by brendonv; 03-23-2014 at 03:45 PM.
Reply:Came out real good.  Good work!
Reply:Looks good..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:You may want to rethink the latch. That is going to be hard to open when the door has weight against it. It will also allow the door to twist, or push out on the bottom. If I was doing it I would use a semi trailer type latch that will hold it top and bottom and be easy to open. They will also help hold the sides from tilting to the side. Otherwise it looks awesome!!! Attached ImagesLast edited by welderj; 03-24-2014 at 11:35 AM.
Reply:Ya im going to see what happens, thanks for,the heads up.  I wanted to keep it simple stupid (kiss), but fear what you say will be true!Last edited by brendonv; 03-24-2014 at 04:08 PM.
Reply:Is there anything else you can recommend?  There isnt enough meat on the side panel to mount that kind of setup.  Theres only an inch and a half thick..
Reply:Possibly the side door setup would work?
Reply:Originally Posted by brendonvPossibly the side door setup would work?
Reply:Ha, thanks man.  I called and they want only $25 for it.  It seems like it would mount nicely.  I just need to make a stop on the door so it doesnt go past closed.  See what happens.
Reply:Originally Posted by brendonvHa, thanks man.  I called and they want only $25 for it.  It seems like it would mount nicely.  I just need to make a stop on the door so it doesnt go past closed.  See what happens.
Reply:I bent the front panel for the roof today.  Got the two sides on too.  I have plastic panels for the very top still to install, and the latches.  Should be good to go in two more days.Ahh Attached Images