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This weekend Dad and I squared up the box as best we could. It's about 1/16" out corner to corner. We then tried to put on the tailgate to attempt square up the gaps and vertical stake pocket posts. This is where the "reproduction" fit reared its head.

Problem 1. With the trunnions in place the tailgate sat too low and couldn't adjust high enough to be flush with the top of the bed side. No big deal. A little die grind of the trunnion holes and I got the necessary up and down.

Problem 2. We closed up the tailgate. Left side looked ok. Right side had problems. The tailgate jams up against the stake pocket post. As it closes, it hit the post near the bottom. This pushes the tailgate out severely, rubs paint, and when closed the top of the tailgate is sticking past flush of the rear by 1/4- 3/8". Very difficult to line up and close.

Solution?

I think I will need to cut down the stake pocket pillar, remove material and weld it back up.

So, in the meantime we changed gears. I wanted to get this bed onto the frame so we cleaned house a bit and put it on the trailer and moved it to the shop so mods can begin. In order to place the box on the frame, the bed wood has to be in between the cross sills and the bed sides. If not, the bed side simply drops down and rests on the frame. The floating sills work against you here. So my pa in law cut me some 3/4" plywood fillers so I can weld, slice and dice with it in position.

Problem 3. I noticed that with the bed wood kit, and an under bed fuel tank, I won't be able to get the nuts on the carriage bolts that bolt the bed to the frame at this location. To do so, I would have to drop the tank and pull line, unhook wires, etc. My fix? I drilled some holes and die grinded an access port so I can get the nuts on the carriage bolts. Tight? Yes. Finicky? Yes, but it should work better than dropping the tank.


Problem 4. The right rear tub doesn't line up with the bedside rear holes. There is a noticeable gap where you can see the hole in the bed side flange. With wood in place, it sticks out like a sore thumb. I believe I will have to cut this tab, and build a new one to fit.

Ugh....progress?

Yes, but always 3 forward, 3 back , 2 forward, 1 back...


Arghhhh! I just realized those access holes are redundant. I will have to drop the tank in order to secure the rest of the wood hold downs that are anchored to the sill...directly above the tank!! Frick.

See how I'm correct about my step theory?