5 Hour PBL Project(More like 25 hours +)

By: Stefan Engelhard

Converting A Long Box Pickup into a Short Box

RATIONALE

• Sportier look• Short box is less common

than Long box• Harder to find and more

expensive • Challenge

Required research

• What parts are different • What requires modification

Box Length Wheel Base

Long Box 8 feet or 96” 127”

Short Box 6.5 feet or 78” 115”

Difference 1.5 feet or 18” 12”

Preliminary Research

• Is it safe? Is it legal? Will it pass a vehicle safety inspection?

• Manitoba vehicle inspections Handbook• Section 8-3 Frame and mounts

– Ok if done correctly

• I-CAR website and Handbook• Proper frame sectioning techniques

TRUCK PROJECT

• 1. The tear down or disassembly

• 2. Cutting the frame and welding it back

together straight

• 3. Modifying the box

• 4. Other modifications required

Tear Down

• Removing the front clip

Tear Down

• Removing the box

Tear Down

• Removing the cab

Tear Down

• Removing the cab

The Frame

Cutting an Welding the Frame

Straight cut Diagonal cut

Cutting an Welding the Frame

Z Type cut

Cutting an Welding the Frame

Cutting an Welding the Frame

Cutting an Welding the Frame

Modifying the Box

Cut 12” front & 8” rear Join and weld back together

Modifying the Box

Butt Weld Clamps

Back up plan

Other modifications required

• Driveshaft needs to be shortened

• Fuel and Brake lines need to be shortened

The End

Resources

• http://67-72chevytrucks.com/vboard/showthread.php?t

• =123624http://www.earlyclassic.com/tech.aspx?category=Longbed,%20No!-Shortbed

• -2https://www.youtube.com/watch?v=NddN52Pe7CQ

• http://www.musclecarrestorations.com/articles/tech/metal-work/welding-sheet-metal.html

Resources

• http://www.hotrodders.com/forum/butt-welding-body-panels-106925.html

• http://www.powerblocktv.com/player/2min_player.php?ep_show=2min&ep_num=2min-

• 05http://www.lmctruck.com/