The Super-Single cab

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Unreal K-ZN
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Real Name: Gareth

Sat Oct 05, 2019 6:54 am

Hi guys and girlsImage
Being a newby to this forum I would like to just start by saying thanks to all of you that have helped me with many answers on this forum before I joined. You guys are awesome.

My title, “Super-single cab” should say it all. I have a single cab, I want the super cab space for camping but I don’t wanna sell my Moose and have to go through all the mods again just for some extra cab space.
After much Captain and many brainstorming nights, as well as some crazy you tube time, I figured the only way to get the extra space would be to do what they do in Aus, build a new “bak” and add a canopy section.
The thing is, I don’t like the tray idea for my lifestyle and this seemed to be a critical elementImage so once again it was back to the Captain and the drawing board.
About half way to the bottom of my last dop, I came up with an idea that was almost too good to be trueImage so straight to google, Hilux forum, other forums, you tube, wiki, freakin anywhere I could think to find out if anyone, anywhere ImageImageImageImageImageImageImagehad undergone such a move before? There were many questions I had, and I could not find a single answer online. Maybe I searched the wrong things but I gave it my all until I just couldn’t be bothered searching anymore. I just had to dive in and try.

My idea is as follows. Step 1, remove single cab bin. 2, fit double cab bin. 3, fill the gap with the ultimate camping setup. 4, still look like a Hilux Image

Step 1 was easy of course, couple bolts and some wiring and Moose lost some weightImage
Step 2 was a bit more tricky due to only 4 of the 6 bolts lining up from the double cab bin to single cab chassis, but that’s easily remedied in step 3.
Step 3 is where I am at the moment in the build and I think I should mention that everything so far and to the end will be a bolt on application. I have not cut or welded anything on the chassis side of the build and nor will I. The idea is that if I wish, I can put the single cab bin back on at any given time with no mods needed.

Some pics so far for you guys, hope you enjoy them and I will post more on this thread as I go. Today I am planning to finish the “super” cab’s welding and grinding and maybe even get a coat of paint on itImage


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FIRSTGEER
LR4WD, Lockers, Crawler Gears
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Sat Oct 05, 2019 8:44 am

Very brilliant idea. I like your way of thinking. Please keep us posted as your build progresses. I cannot wait to see the finished job
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Mud Dog
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Real Name: Andy
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Sat Oct 05, 2019 10:10 am

Awesome idea! :thumbup:
Keep us posted.
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
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Mud Dog
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Real Name: Andy
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Sat Oct 05, 2019 10:12 am

Maybe some gull-wing doors and a sliding tray on each side? :think:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!
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Unreal K-ZN
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Real Name: Gareth

Sat Oct 05, 2019 2:40 pm

Mud Dog wrote:Maybe some gull-wing doors and a sliding tray on each side? :think:
Without a doubt the full wings, one for the fridge slide on one side and the shower rose on the other one. Image



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Unreal K-ZN
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Sat Oct 05, 2019 2:41 pm

FIRSTGEER wrote:Very brilliant idea. I like your way of thinking. Please keep us posted as your build progresses. I cannot wait to see the finished job
Thanks a mill. It’s been quite a jol so far, looking forward to bolting it on Image


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pieta.swanepoel
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Mon Oct 07, 2019 6:59 am

Creative thinking. Like the idea and would not be as heavy as a fill tray style canopy
Groot berge en lang grondpaaie
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Bear
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Mon Oct 07, 2019 11:52 am

Hi Gareth

I see the guys giving you credit for a job well done.

I was going say great stuff, very original. That is what engineering is!

And as I continued reading and you stated - “After much Captain” … “About half way to the bottom of my last dop”
I’m not sure if you deserve the credit for this work anymore.

Be a gentleman, give the credit to "CAPTAIN"
Travel is not really about leaving our homes, but leaving our habits.
Adventure tends to magnify all human emotions.
It's only in adventure that some people succeed in knowing themselves - in finding themselves.
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FIRSTGEER
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Mon Oct 07, 2019 12:49 pm

Gareth another very important aspect of your project which I fully agree with,is to use the origonal mounting points on the chassis without welding and cutting anything on the chassis.
I have completed many projects over the years, including engine conversions and campers etc and have always applied this golden rule of keeping mounting points etc standard so one can always revert back to the standard vehicle setup should the need arise for whatever reason.
We are waiting in anticipation for further updates. :thumbup:
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Unreal K-ZN
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Mon Oct 07, 2019 4:54 pm

Bear wrote:Hi Gareth

I see the guys giving you credit for a job well done.

I was going say great stuff, very original. That is what engineering is!

And as I continued reading and you stated - “After much Captain” … “About half way to the bottom of my last dop”
I’m not sure if you deserve the credit for this work anymore.

Be a gentleman, give the credit to "CAPTAIN"
All due respect to Captain Henry Morgan. Image


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Unreal K-ZN
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Mon Oct 07, 2019 4:55 pm

FIRSTGEER wrote:Gareth another very important aspect of your project which I fully agree with,is to use the origonal mounting points on the chassis without welding and cutting anything on the chassis.
I have completed many projects over the years, including engine conversions and campers etc and have always applied this golden rule of keeping mounting points etc standard so one can always revert back to the standard vehicle setup should the need arise for whatever reason.
We are waiting in anticipation for further updates. :thumbup:
I agree, if this mission turns out to be a lemon, I can always drop my long bin back on and not have to worry about anything except for my loading bars which will just be lengthened again to suitImage


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Unreal K-ZN
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Tue Oct 08, 2019 5:31 am

Some work in progress pics. Please don’t judge my weldingImageImageImageImageImage[IMG]//uploads.tapatalk-cdn.com/201910 ... d9a507.jpg[/IMG]ImageImageImageImageImageI am a carpenter by trade, not a welder, this job has taught me a lot about welding thoughImage


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Unreal K-ZN
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Tue Oct 08, 2019 5:34 am

Sorry about the random order. They appear to load in reverse Image

ImageImageImageImageImageImageImageImageImage


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Mud Dog
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Real Name: Andy
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Tue Oct 08, 2019 9:02 am

Looking good Gareth! :thumbup:

We can't all be professional welders, but with the will to give it a go and a little practise we can all make a go of it,. So what if you have to do a bit of grinding to smooth it off afterwards. :winkx:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!
Poffie
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Wed Oct 09, 2019 5:54 pm

I agree with Mud Dog not all pretty welds is strong. Well done at least you can be proud you are doing it yourself. Nothing trumps that 💪🏼
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Dowe Koos
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Fri Oct 11, 2019 3:10 pm

Hi Gareth. I'm very keen to see your end product. So far, it's looking interesting on how you progress. I am going show you some photos to give you some ideas about basic welding. I mean it good, not in negative way.
First of all, I never grind off my welding for it is weakened the structure, ALWAYS. I will only grind off the weld where something flat must fit on and only that. Only weld where I will grind off is when I had V weld joint.
Top one is a gap of 1 mm, middle is normal joint and the bottom one is where the V is prepared.
001 three plate.jpg
This is show you how the weld had penetrate through the plates.
002 penetrating of weld.jpg
002 penetrating of weld.jpg (33.71 KiB) Viewed 345 times
I haven't grind of the weld of all three plates.
Bending the V weld joint
003 bend v.jpg
004 bend v 2 gap.jpg
Bending the normal joint weld
005 bend no  gap.jpg
006 bend no gap 2.jpg
Bending the gap joint weld
007 bend with gap.jpg
008 bend with gap 2.jpg
I had bend all three plates a few times.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Dowe Koos
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Fri Oct 11, 2019 3:15 pm

Now I had grind off the weld.
009 grind off weld.jpg
Bend the one with V joint
010 bend v gap.jpg
011 bend v 2 gap.jpg
011 bend v 2 gap.jpg (27.75 KiB) Viewed 343 times
Bend the one of normal joint
012 bend no gap .jpg
013 bend no gap 2 .jpg
Bend the one with gap joint
014 bend with gap.jpg
014 bend with gap.jpg (32.38 KiB) Viewed 343 times
014 bend with gap 2.jpg
014 bend with gap 2.jpg (33.69 KiB) Viewed 343 times
015 bend.jpg
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Dowe Koos
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Fri Oct 11, 2019 3:29 pm

Bend the one with the V joint weld a few more times
016 v bend few times.jpg
Bend the one with normal joint weld one more
017 bend no gap one more.jpg
017 bend no gap one more.jpg (33.83 KiB) Viewed 340 times
018 bend no gap one more.jpg
Bend the one with the V joint weld extra few more times
019 bend v few more tine.jpg
Here you can see how important is your preparations.
Other important thing about arc weld is the heat. If you weld over and over the weld to fix it, it is weakened the metal composite and can give you problem when you do some over landing where it is getting rough. I understand that you are a carpenter and is not a welder. I would suggest to you to practice more on your weld so that your project is well done and will not give you problem later on.
Hoop nie ek is windgat nie, wil maar net help.
Sterkte met jou projek.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
Thabogrobler
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Sat Oct 12, 2019 10:08 am

Nee, Oom Hennie is nie windgat nie - hy weet darem so iets meer van welding as die gemiddelde ou op straat!
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Dowe Koos
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Sat Oct 12, 2019 10:58 am

Dankie Thabo.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Unreal K-ZN
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Real Name: Gareth

Tue Oct 15, 2019 3:50 pm

Hi guys. Thanks for all your input and positive feedback. Progress a bit slow at the mo, work getting in the way of fun againImage

I have managed to paint the frame and fit the floor panel ally in, this let’s me get an idea of fridge slide positioning and batteries spacing. Gotta get some templates made so I can take the rest of the ally for bending.
Would love to get the skins on before December creeps up in low rangeImage

ImageImageImage


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Mud Dog
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Real Name: Andy
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Tue Oct 15, 2019 6:10 pm

Still looking good and slowly getting there, Gareth. Well done so far. :thumbup:
When your road comes to an end ...... you need a HILUX!.

Image
Image

Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!
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