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Old 06-23-2013, 10:25 PM   #47 (permalink)
Master EcoModder
Join Date: May 2010
Location: Illinois
Posts: 428

Oh Deer - '03 Ford Ranger XL
90 day: 33.16 mpg (US)
Thanks: 51
Thanked 70 Times in 54 Posts
Here you go JR.

I took steel 1/2" steel EMT couplings and drilled out the little nub on the inside that keeps the coupling from sliding all the way down the pipe. The two screws on the coupling are between the "jaws" of the workbench I used. Then filed off the crud so the coupling would slide down the pipe. This made assembly much easier. Then I had a friend tack weld the couplings together to make the T shaped pieces on the bottom and the stacked pieces on the top of the picture. The stacked pieces are for the "sliding" idea I have to have access to the bed. or at least as much of it as I need. That's the next step after I get the shape right. It works in my mind but we'll see how it works in reality. Cross your fingers.

After that it was a lot of trial and error to get the pieces bent and fitted. I leveled out the old wrecked bed on the garage floor to give me a good starting point and checked it between building each rib to keep everything as level as possible. The pictures of the frame on the bed don't look very square but as I said the rain was coming. I used an angle finder to check the slope angles and a tubing cutter to give me nice square cuts on the EMT.
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