Cutting Up My Truck

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Peterb

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fwiw my king 3.5s have hoses and remote reservoirs and also I got drop shackles, both change the shape and size of the holes compared to piggyback reservoirs and stock shackles
 
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Psirus7

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I finally started getting my truck together after waiting for the Inland NW winter to be over. Dovetail is almost done, but I have a lot of cleaning up to do on the plastic. I used a 3" cut-off saw and found that it melted the plastic pretty bad. I'm hoping that sanding and a razor blade will clean up the cut. I popped out the plastic and cut the metal about 1/3" higher than the plastic. I also cut the bottom off the rear frame horns about 3". My garage is covered in aluminum and molten plastic bits...Dovetail.jpeg
 
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Psirus7

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My measurements for the SVC Mojave rear was about 2.6" down from the plastic at the rear corner, and about 8.1" down to the crease. A flap wheel cleaned up the metal edge really nicely and I used a combination of a 3" cut-off tool, Dremel with a metal cutting blade, and an (air) body saw.Rear .jpg
 
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Psirus7

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I used a dull flap wheel and a razor blade on the plastic to smooth out the cut on the plastic trim. It’s not perfect, but it is greatly improved!
 

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Psirus7

Psirus7

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Finally knocked out the cuts in the bed for my bypass rack. I went 8.5” back from the front of the bed and 20” to the rear. I offset 1.75” on the side and tapered the cut to a 1/2” edge along the bedside. I used a 4.5” cut-off tool, but most of the cutting with with a dremel metal cutting blade (yes, it took forever). I rounded off the corners with the dremel router blade. I undercut any awkward angles and then used a flap disk to get the cut within spec.
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downforce137

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Something I didn’t expect was the crazy spiderwebbing that came from cutting through two layers of line-X.

yeah.. cool fumes, right? I just took a pressure washer to mine the other day and most of the sprayed line from the wheel came off, a year later..
 
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