I panned about 85% of my truck so far.
The frame of the truck is not straight. It bends up near the forward leaf spring mounts.
To keep a frame jack point accessible, I made a jacking extension with 4" channel and 2" heavy angle. It is bolted to both the frame flange and the face of the frame, using existing and new bolt holes. After I fabbed those, I installed them and then jacked the truck on the new extensions.
For the framework, I used some galvanized channel from a surplus metals yard. Each 10' length weighs 2.8 pounds and I picked up 10 for $14.
I utilized 1/4" threaded rod and nuts, drilled and tapped the frame to stand off the channels.
This made the whole grid work adjustable. When I had it the way I wanted, I trimmed off the excess rod.
Some of the channel and rod "foundation".
Looking forward, you can see the crossmember is the lowest point.
Where I could not get a good parallel surface, I welded on tabs to drill through.
Here is the detail around the left A-frame. I can adjust the front framework lower if needed.
Same area, farther back and outboard. Note that I triangulated the channel to give it some stiffness.
front area is about done.
coroplast is attached with self drilling #10 screws and 3/16" fender washers. It was installed back to front, with simple lap joints.
It is below the front frame, so a pocket is needed for hoisting up there. I could go back and make a frame extension in this area if I desire.
cut a window out below the muffler. It was the closest part to the pan, so I will let some of the engine cooling air out there.
same area looking forward. I did not go below the tank and went around it. I did not want to get the pan lower in the back under any circumstance, I wanted it to relieve pressure as it went aft. Going under the tank looked to be too much.
folded detail of front corner. This area will be behind a new bumper/spoiler but I had to finish it off and keep the truck going till then.
Today I brainstormed on that last 3 feet. I can go below the spare and close it in completely. I'll cut a door in the belly to get the spare out if needed. This got the angle to near 4 degrees.
I cannot maintain that to the outside edges due to the design of the boxes, so it will be tapered to the left and right.
you can see the taper in the framework here.
What the shop floor looked like after last night's flurry of trimming. I call it a "coroblast".
I'm one sheet short
The back will go unskinned till I get back on the hoist and have the materials.