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Old 13-09-20, 23:22
Grant Bowker Grant Bowker is offline
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Join Date: Jul 2006
Location: Ottawa, Canada
Posts: 2,285
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The reinforcing strips were spot welded to the body of the box, then welded closed at a corner. We were pleasantly surprised how well the spot welder performed on the unequal thicknesses of this joint. Rather than spot welding the end cap on, we used modern auto-body repair glue. Long reach spot welder tongs are expensive for a rarely used application.... and the lack of spot weld dimples isn't really going to be visible under the truck body. Straps were made to attach the boxes to the body. The originals didn't show signs of anything more than friction holding the boxes into the straps. Parts were made to allow for locking the boxes, drilled in pattern to match originals.
Attached Thumbnails
box 6 - reinforcement welded.jpg   box 7 - end cap glue.jpg   box 8 -body assembled.jpg   box 9 - mounting straps.jpg   Box 10 - clousure parts.jpg  

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