C&C to super bed conversion - bed extension

[mopar346]

Well those of you who have paid any attention to my babbling and rambling about my C&C know that I decided to use a regular long wheelbase bed and extend it to meet the cab. The first thing I had to do was remove my flat bed, locate a base bed and donor bed. Once a bed was located I had to move the wheelwells in to make it clear the dual rear tires. In order not rehash that process I have posted a link to that thread in the case anyone needs to see it. I will also post a link to this thread as a final post on the tubbing thread.

http://67-72chevytrucks.com/vboard/s...d.php?t=539090

This thread will be about the bed extension process.

[mopar346]

Well Monday night I couldn't sleep with the full moon so I figured out my plan of attack on the bed extension (isn't life great when that is all I have to worry about). I decided 2 things, one I would do it on the truck and two I would take it apart to move it over. Then yesterday afternoon I went to Lowes to get a couple of fresh metal blades for the skill saw and went to cutting.

The first thing I did was cut the floor section that I am gonna use out and unbolt it. I cut long so as to be safe, pretty much cut it even with the front of the wheel well. I had to trim the well flange and the flange on the side that would overlap the area it sits on the original bed.

Next I cut the bottom portion of the front of the original bed off. This would allow me access to slide the floor in and fit it while still holding the top of the bed sides at the proper alignment. I also had to trim (and fold back) the flange that the front panel bolts to so my floor cut out would slide in. It all worked perfectly except the third cross brace on the bed section was at just the right depth to stop me from getting the right gap between the cab and the bed. This afternoon if the weather allows I will cut the brace off and finish fitting the floor.

Pease keep in mind I haven't done this before so question anything you see, it may be something I haven't thought of and same me a mistake or 12.

[mopar346]

Today I was able to fit the bed floor and the pass flank, sorry the pictures aren't that good but you can get the idea. My phone died before I got the flank fitted so I will have to post the pictures of how I modified the bed side end and of course the flank in place.

First thing I did was cut the third brace off, grind the remander of the welds off and prime the area, you can see the black primer in the first picture. Once I did that it slipped right in with about a 4-5 inch overlap. I measured from the back of the bed not the cab to try and keep it square and temperarily secured it with 3 sheet metal screws. It is just a temperary fit, its ultimate positioning will be dictated by the bed side and front, then I will trim the overlap to just where the original floor ridges tapper flat and weld it in place. All in all very pleased with how it laid down.

[mopar346]

Next I cut the passenger's flank off of the donor bed. I cut it long as to plenty to work with. In the preliminary fitting I overlapped the sides but in the end carnation the inside will overlap and the outside will be butt welded.

Before I could fit the flank I had to remove the rest of the bed bulkhead. I still had the concern of it holding its position so I took the brace I had cut out and made a support to hold the bed sides.

I had to modify the bed side end so that it could overlap inside and out, including notching out for the hold down box. I folded the inner layer of the bed rail down to make a mating tab for the front lip of the original box, kinda a tab A to tab B and weld on the dotted line thing. I will get pictures of the configuration tomorrow when I pull it back off for trimming.

[mopar346]

Here are the pictures of the modification to the bed end of the flank to creat the welding tabs and fit around the holddown box. There is also a couple of pictures of the passenger side flank mounted. This is where I started today.

[cory d]

its like a long horn. you should make a long horn badge that says "loooooonghorn"

[mopar346]

Today I pulled the passenger side flank back off and trimmed some areas for a little better fit and then remounted it. Then I put the front of the bed in, cut the driver's side flank out and trimmed it to fit. I was able to use the passenger side as guide for some of the measurements and it went in with a little finess and on truck trimming. I have it all screwed together for the moment. On my next break I will pull it all back apart, blast, treat and prime it and dot he final assembly for welding. All in all it went together pretty easily and I like the fit. I measured from the front of the back holddown box to the rear of very front (the added one) holddown box, side to side I was less than a 1/16 off, which feel pretty good about. Total box length, 10.5 ft from tailgate to front of the box. Here is the final pictures---for now.

[6 Door King]

Your post is exactly what I envisioned for my GMC6000 Crew Cab with utility bed. I even went so far as to buy a long bed to hack up, then flipped the truck in favor of a Crew Dually 2WD w/ 454 so I now have the regular long bed. I like the way you went about extending the bed, are you adding extra mounting bolts too?

[mopar346]

Thank you, 4 doors with this bed would be crazy long. Yes on the bolts, the front 2 bed bolt wholes from the donor bed are in tack and I plan to drill the frame to match. I want to get it welded up and position the bed correctly before I do it. I had to free hand the bolts that currently holds the bed on and from the way everything is lining they're pretty close.

[Dieselwrencher]

Nice work! You can really haul some stuff with it now!

[mopar346]

Mega parts hauler, built for buying junk Mopars, put the car on the trailer and all the parts in the bed.

[1985-GMC]

Cool stuff, I like it!
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[Pop's C-10]

that looks neat

[meatwagon83]

you can put one of those tool chests in it and not lose any room

[mopar346]

I wanted different, I definitely got it.

The trick is gonna be saw toothing the floor to integrate it properly, the side both inner and outer wont be a big deal to mate without leaving evidence. The goal is to not be able to find the joint with minimal bondo.

[Hankster]

BUMPPP* Any updates on this?

[mopar346]

Not other than I use the cr@p out of it, got it useable and haven't gone back to weld everything up. Made a trip to PA in it pulling a trailer and have a second one planned this week end. I've built 3 vehicles since this one so no rest for the weary. I appreciate all the positive responses, it's been a great $1500 dually.

[84chevyguyid]

You should do a "Fall Guy" hidden front compartment on it, still end up with an 8 foot box to use, lol

[Prerunner1982]

Good looking CJ7 too..

[hatzie]

A longhorn extra dually...
Looks like a cool project

[Oregoon]

Super cool! Keep it up and keep posting photos.

[bnoon]

There has been an '87 on Craigslist that had the flatbed removed and I've thought about doing this to it. It was a really clean truck too... hummmm