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Project Number 66 April 2002 Flatbed & Water Tank Design for M1008 and Commercial Pickups National Association of State Foresters in Cooperation with Michigan’s Forest Fire Experiment Station

Flatbed & Water Tank Design for M1008 and Commercial Pickups

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Page 1: Flatbed & Water Tank Design for M1008 and Commercial Pickups

Project Number 66 April 2002

Flatbed & Water TankDesign for M1008

and Commercial PickupsNational Association of State Foresters

in Cooperation withMichigan’s Forest Fire Experiment Station

Page 2: Flatbed & Water Tank Design for M1008 and Commercial Pickups

1

REC Project No. 66

Flatbed & Water Tank Design forM1008 and Commercial Pickups

Table of Contents

Disclaimer...................................................................................................... 1

Introduction ................................................................................................... 2

Data Summary .............................................................................................. 2

Photos ........................................................................................................... 3

Fabricating the Flatbed ................................................................................. 4

Attaching the Bed to the Truck Frame.......................................................... 4

Fuel Fill Location ........................................................................................... 4

Mounting the Tank and Accessories to the Bed ........................................... 4

A Note About Vehicle Loads......................................................................... 5

Drawing List .................................................................................................. 6

Appendix A - Slip-On Tank References........................................................ 8

Appendix B - Poly Tank Specifications......................................................... 9

Appendix C - Drilling Holes in Truck Frame ............................................... 11

Roscommon Equipment Centerc/o Forest Fire Experiment Station1337 East Robinson Lake RoadP.O. Box 68Roscommon, Michigan 48653Telephone: (989) 275-5211Fax: (989) 275-8249Email: [email protected] Site: www.RoscommonEquipmentCenter.com

Disclaimer

This report has been developed for the guidance of member States, Provinces, Federal Agencies and their cooperators. TheNational Association of State Foresters and the State of Michigan assume no responsibility for the interpretation or use of thisinformation.

The use of trade, firm or corporation names is for the information and convenience of the user. Such use does not constitute anofficial evaluation, conclusion, recommendation, endorsement or approval of any product or service to the exclusion of others, whichmay be suitable.

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Introduction

The M1008 is the military version of GeneralMotors 1980’s pickup trucks. Rated at 5/4 Tonpayload capacity, the M1008 is part of themilitary’s commercial utility cargo vehicle(CUCV) family. This project converts an M1008to a flatbed truck by removing the cargo box andfabricating a steel bed. The design can also beused with GM civilian trucks of that vintage.With minor changes, it can be used with virtuallyany standard size, 8 foot bed pickup. Theflatbed offers three advantages over the cargobox.

§ More area is available to mount fireequipment.

§ The bed is more durable than the cargo box.When off road, it can better withstandbrushes with objects such as trees.

§ The sides are lower, making access easier.

The layout and photos show this concept with a175 gallon polypropylene tank mounted to thebed. This tank was designed specifically for thisapplication. The tank is wider than a typicalpickup slip-on tank unit. This allowed a reducedheight, making the top mounted hose reel easierto reach. It also allows the tank length to remainrelatively short so that a pump and foamproportioner will fit at the back of the bed. Thetank’s water capacity was matched to the truckload capacity. Fully outfitted minus storageitems, this unit weights about 88 percent of its

Gross Vehicle Weight Rating (GVWR). Thisallows for adequate storage weight plus acushion to reduce the possibility of operatingoverweight.

Appendix A lists some slip-on tank referencesand custom tank sources. Appendix B detailsspecifications for purchasing the polypropylenetank. Custom building of “poly” tanks can bedone by manufacturers at a reasonable price.Plastic sheet is normally cut by computercontrolled cutters. Because there are no specialmolds and part of the fabrication is automated,there is less advantage to mass production. Thecost of the tank for this project should be about$1,200. The model of pump and its placementwill dictate the location of tank ports. Make suretheir locations are specified properly.

This is not a true slip-on unit. The tank, pump,and most other appliances are mounted directlyto the bed. They cannot be slipped off/on asone unit. Most of the accessories are availablefor purchase. The draft hose storage tubes arean exception. They are mounted by fabricatedbrackets and made of PVC pipe. A step androcker panel guard (“Nerf” bar) was added underthe cab. These bolt to the frame and provide astep and some protection to the cab’s rockerpanel. Trailer hitch, tow point, and tail lightreceptacles are incorporated into the rear panelof the bed.

Data Summary

REC “Flatbed” Slip-on M1008

Weight of vehicle, including pump, proportioner, tank, reel, and storage trunk without stored items.

Weight Rating w/o Water w/WaterFront Axle 3,800 3,405 3,495Rear Axle 5,600 3.445 4,795Total Vehicle 9,400 6,850 8,290

Wheelbase - 131.5 inchesWater Tank Capacity - 175 gallonsWater Tank Material - PolypropyleneFlatbed Material - Steel

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Photos

The finished M1008 product with accessories that REC used.

The M1008 has an outside the frame fuel tank which should be guarded.

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4

Fabricating the Flatbed

The final weight of the steel bed is just over 700pounds. The overall dimensions will be about 8feet x 6-1/2 feet. You will need to prepare anarea large enough to build and turn over astructure of this size and weight.

The welding can be done with either stickelectrode or wire-feed. The later will be faster.Most parts can be cut with a metal capablebandsaw. Plasma cutting is the easiest way tocut the large sheet steel openings. Analternative for those who do not have a plasmacutter or large shear is to have a steel

warehouse prepare the parts. Most have theequipment to do this efficiently. The extra feemay be well worth it.

NOTE: The holes drilled in the deck plate weremade to accommodate specific accessories.Pattern, size, and quantity, will depend onspecific equipment used.

The drawings call for welding the steel tubeframework then adding the deck to theframework. The location of holes in deck withdepend on the fire appliances used.

Attaching the Bed to the Truck Frame

The bed is attached by two bolts located at therear of each frame rail and two rubber cushionedpoints in the front. Section A-A of Drawing 29-9817 shows the rear mount. This is a directmount with a hole drilled in each frame rail and a3/4 inch bolt, nut, and washer tightened to formthe attachment

The “cushioned” points use two of the elastomermounts from the removed cargo box. Theseelastomer mounts are shown as Item 24 on the

Assembly Drawing 29-9817. Detail A on thatdrawing shows the mounting which uses a 3/4inch bolt and nut as the fastener and the existingframe hole used by the cargo box mount. Thisprovides an isolated attachment in the front,allowing the truck frame to twist as it travelswithout undue interference from the bed. Thisallows the bed to “float” on the frame as theframe twists during travel. Appendix Cdiscusses do and don’t about drill holes andwelding on frame rails.

Fuel Fill Location

When locating the vehicle’s fuel fill opening,choose a location no lower than it was on thecargo box. If you are using this information as aconcept for a purchased cab and chassis,

consult the manufacturer for the fill openingdimensions. These are found in their “BodyBuilders” publication.

Mounting the Tank and Accessories to the Bed

Because the bed plate is of substantial strength,accessories can be bolted directly to it. Auxiliarypump engines should be mounted on motormounts to accommodate vibration. Study the

placement of these items to make sure thevehicle is balanced. More on this is found in thefollowing section.

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5

A Note About Vehicle Loads

The operating weight of the vehicle must bewithin the safe limits determined by the vehiclemanufacturer. The manufacturer of each truckdetermines the Gross Vehicle Weight Rating(GVWR) for that vehicle. The GVWR is themaximum design load. The manufacturer alsolists the Front Axle Weight Rating (FAWR) andRear Axle Weight Rating (RAWR). These arethe maximum design loads on each axle. Noneof these ratings should be exceeded. Forwildfire control uses, it is good practice to reducethe load. A fire truck is fully loaded almost allthe time. This is a heavier duty than theaverage pickup truck use profile. Loading thetruck at 85 to 90 percent of the weight ratingswill reduce operating costs, extend the life of thetruck, and provide a margin to allow for someadditional equipment beyond the standardcompliment.

Weigh the final vehicle, fully loaded foroperation, before putting it in service to assurethat it does not exceed weight limits.

REC provides other resources related to thissubject listed below. They can be found atwww.RoscommonEquipmentCenter.com.

Project No. 61, Slip-On Water Tank Units:Discusses topics important to selecting and

installing a slip-on tank on a pickup truck. Muchof this information relates to flatbed designs aswell. The contents include material selection,securing the tank unit to the vehicle, and properloading of the tank. There is a listing of otheruseful publications, designs, and tank retailers.The online version is downloadable using AdobeAcrobat Reader.

Newsnote No. 3, Guidelines for DesigningWildland Fire Engines: This is a primer for thoseplanning to fabricate a fire truck. It includesbasic design needs, legal, and safetyrequirements, and a list of other resources. Theonline version includes hyperlinks to otherresources.

Slip-On Engine Weight Calculator: Located onREC’s web site, this calculator provides asimplified version of the “Wildland EngineWeight Calculator” which is designed specificallyfor those installing a slip-on tank into a pickuptruck cargo box. It also can be used during thedesign process to help determine the placementof components on the engine and to determinetank size. For this calculation, the user mustenter the weight and location of the componentsto be added to the truck. An estimated finishedweight is provided, plus a brief analysis of theviability of the load.

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Drawing List

OVERALL ASSEMBLY

Drawing Number Drawing Name29-9817 5/4 Ton Bed and Nerf Bar A/C

TRUCK BED DETAILSDrawing no. 29-0085 is the overall weld complete of the truck bed. It is followed by the Truck BedSubweld, which is the skeletal framework for the complete bed. The detail prints of individual parts followthese two drawings in the order listed below.

Drawing Number Drawing Name29-0085 Truck Bed W/C00-1381 Truck Bed S/W00-0123 Tie Down00-1355 End Rail00-1356 Side Rail00-1357 Crossmember, Long00-1358 Crossmember, Short00-1359 Frame Rail00-1360 Headache, Vertical00-1361 Headache, Angle00-1362 Headache, Top00-1363 Headache, Cross00-1364 Bumper, Lower00-1366 Gusset, Receiver00-1367 Bumper, Angle00-1368 Mount Bar, Rear00-1369 Mount Bar, Front00-1370 Gusset, Rear Mount00-1371 Side Rail, Top00-1372 Side Rail, Rear00-1373 Side Rail, Vertical00-1374 Bracket, Side Marker00-1375 Deck, Rear00-1376 Deck, Front00-1377 Mount Pad, Front00-1378 Gusset, Front Mount00-1379 Cover, Rear LH00-1380 Cover, Rear RH00-1448 Fuel Tank Guard, Mount00-1449 Fuel Tank Guard, Side00-1450 Fuel Tank Guard, Rear00-1452 Mount, Work Light00-1453 Expanded Metal Headache Rack00-1454 Receiver, Sides00-1455 Receiver, Top-Bottom00-1456 Receiver S/W00-1457 Bracket, Fuel Fill00-1467 Mount Tab28-8007 Light Mount Bracket29-0088 Tank Guard W/C

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STEP AND ROCKER PANEL (NERF) GUARDThe step and rocker panel guard is an independent assembly and can be added or deleted from theproject. Drawing 29-0086 shows the completed weldment with part details and subwelds following.

Drawing Number Drawing Name29-0086 Step, Rocker Panel Guard W/C00-1435 Pipe, Front00-1436 Pipe, Side00-1437 Pipe, Rear00-1438 Mount, Rear00-1439 Gusset, Rear00-1440 Mount, Front00-1441 Gusset, Front00-1442 Cap, Front Pipe Notch00-1443 Stiffener, Rear Mount00-1444 Top, Rear Bracket00-1445 Vertical, Rear Bracket00-1446 Bottom, Rear Bracket00-1447 Stiffener, Rear Bracket29-0087 Bracket, Rear W/C29-0089 Spacer, Front29-0090 Spacer, Rear

Page 9: Flatbed & Water Tank Design for M1008 and Commercial Pickups

STD. TOL.

DECIMAL:1 PLACE + - 0.062 PLACE + - 0.033 PLACE + - 0.005

ANGULAR:+ - 1 DEG. N0. BY DATE REVISION

P.O. BOX 68 ROSCOMMON, MICHIGAN 48653

TITLE:PROJECT NO.:

SCALE:

DWG. NO.

DESIGNED:

FOREST, MINERAL AND

FIRE MANAGEMENT

DATE:

DRAWN:

APPROVED:

FOREST FIRE EXPERIMENT STATION

DSIZE:

FRACTIONAL:0 TO 6 IN + - 1/326 IN AND UP + - 1/16

A

A

1-1/4

1-3/4

( )3-1/2

5/4 TON , BED AND NERF BAR A/C 29-9817

DGP

DGP

*

05-Dec-2001

1/8

ITEM PART NO. DWG DESCRIPTION QTY

1 29-0085 D TRUCK BED W/C 12 29-0086 C STEP, ROCKER PANEL GUARD W/C 13 29-0087 B BRACKET, REAR W/C 24 29-0088 B TANK GUARD W/C 15 29-0089 A SPACER, FRONT 26 29-0090 A SPACER, REAR 27 00-1467 A MOUNT TAB 18 TS-05GG06 SCREW, HEX HEAD CAP 5/16-18UN X 3/4 GR 5 PLTD 49 TS-06GG08 SCREW, HEX HEAD CAP 3/8-16UN X 1 GR 5 PLTD 3

10 TS-06GG10 SCREW, HEX HEAD CAP 3/8-16UN X 1 1/4 GR 5 PLTD 411 TS-08GG12 SCREW, HEX HEAD CAP 1/2-13UN X 1 1/2 GR 5 PLTD 412 TS-12GG16 SCREW, HEX HEAD CAP 3/4-10UN X 2 GR 5 PLTD 213 TS-12GG24 SCREW, HEX HEAD CAP 3/4-10UN X 3 GR 5 PLTD 214 TS-05GP NUT, HEX 5/16-18UN GRADE 5 PLATED 415 TS-06GP NUT, HEX 3/8-16UN GRADE 5 PLATED 716 TS-08GP NUT, HEX 1/2-13UN GRADE 5 PLATED 417 TS-12GP NUT, HEX 3/4-10UN GRADE 5 PLATED 118 TS-12GPL NUT, HEX LOCK 3/4-10UN GR 5 PLTD 319 WS05-BC WASHER, LOCK 5/16, SPRING TYPE, REG PLTD 420 WS06-BC WASHER, LOCK 3/8, SPRING TYPE, REG PLTD 721 WS08-BC WASHER, LOCK 1/2, SPRING TYPE, REG PLTD 422 WS12-BA WASHER, FLAT 3/4, USS PLATED 423 PIPE CLAMP, 3 1/2" 124 RUBBER FRAME BUSHING 225 5/4 TON CAB 126 5/4 TON FRAME 1

8

A

SEE DETAIL A

SEE DETAIL B

DETAIL ASCALE 1/4

1

2

4

6

8

9

11

13

23 24

15 20

22 18

2116

14 19

USE EXISTING HOLES IN FRAME

USE EXISTING HOLES IN FRAME USE EXISTING HOLES

IN FUEL TANK SKID PAN

SEE SECTION A-AFOR DETAILS

5

11 16 21

DRILL 17/32ø HOLE IN ITEM 5 AND ITEM 6 (00-1440) OF 29-0086C USE EXISTING HOLE IN FRAME FOR LOCATION

15 2010

3

DETAIL BSCALE 1/4

1419

4

7

USE EXISTING HOLE INFUEL TANK SKID PAN FORLOACTING ITEM 7

12 17 22

DRILL 25/32ø THRU ITEM 9 OF 00-1381D AND FRAME LOCATE HOLE CENTER OF FRAME (ITEM 26)

26

1

SECTION A-ASCALE 1/8

1/8

PILLOWD
PILLOWD
Page 10: Flatbed & Water Tank Design for M1008 and Commercial Pickups

STD. TOL.

DECIMAL:1 PLACE + - 0.062 PLACE + - 0.033 PLACE + - 0.005

ANGULAR:+ - 1 DEG. N0. BY DATE REVISION

P.O. BOX 68 ROSCOMMON, MICHIGAN 48653

TITLE:PROJECT NO.:

SCALE:

DWG. NO.

DESIGNED:

FOREST, MINERAL AND

FIRE MANAGEMENT

DATE:

DRAWN:

APPROVED:

FOREST FIRE EXPERIMENT STATION

DSIZE:

FRACTIONAL:0 TO 6 IN + - 1/326 IN AND UP + - 1/16

F

F1/4

79

39-1/16

19-1/16

1/81-1/41-1/4

6-15/169

10

2-3/4

2-1/16

6-13/16

2-9/16

30-7/8

12-3/4

2-1/8

19-3/4

5-5/8

9-1/8

ITEM PART NO. DWG DESCRIPTION QTY

1 00-1381 D TRUCK BED S/W 1

2 00-1360 A HEADACHE, VERTICAL 2

3 00-1361 A HEADACHE, ANGLE 2

4 00-1362 A HEADACHE, TOP 1

5 00-1363 A HEADACHE, CROSS 1

6 00-1371 A SIDE RAIL, TOP 2

7 00-1372 A SIDE RAIL, REAR 2

8 00-1373 A SIDE RAIL, VERTICAL 16

9 00-1375 C DECK, REAR 1

10 00-1376 B DECK, FRONT 1

11 00-1379 B COVER, REAR LH 1

12 00-1380 B COVER, REAR RH 1

13 00-1453 B EXPANDED METAL, HEADACHE RACK 1

14 00-1452 A MOUNT, WORK LIGHT 2

15 28-8007 B LIGHT MOUNTING BRACKET 2

16 00-0123 A TIE DOWN 4

TRUCK BED W/C 29-008500-6

DGP

KDB

*

14-May-2001

1/16

PART NO: 29-0085EST WT: 712.05 LBS

TYP

14 PLCSTYP

6

8

7

910

11

12

16

3

5

4

2 2

1

13

15

SECTION F-FSCALE 1/4

13

15

14

16 PLCS1/8

TYP 1/8

TYP 1/8

TYP

3 SIDES 1/8

3 SIDES 1/8

1/822-6-6

5 PLCS1/8

22-6-6

3 SIDES 1/8

1/8TYP

4 PLCS

TYP

TYP 1/8

1/82 SIDES

TYP

1/8TYP

1/8 1/8-1 1/2

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Appendix A - Slip-On Tank References

The following references include additionalinformation on this topic. Suppliers names arelisted for the convenience of the reader andshould not be taken as an endorsement, nor is

the supplier listing complete. It is certain thatthere are many small slip-on manufacturers notincluded in the documents listed below.

ReferencesWater Handling Equipment Guide, NationalWildfire Coordinating Group, March 1994. Thispublication has photographs and listsspecifications for wildland fire units across theNation. Some of these are slip-on type units.Order NFES #1275 from the NationalInteragency Fire Center, ATTN: Great BasinCache Supply Office, 3833 South DevelopmentAvenue, Boise, Idaho 83705.

Wildland Fire Engine Component Guide,National Wildfire Coordinating Group, March1994. Lists and discusses common components

found on wildland fire vehicles. This publicationhas chapters which discuss tanks, pumps, andother components. Order NFES #1871 from theNational Interagency Fire Center, ATTN:Supply, 3905 Vista Avenue, Boise, Idaho83705.

REC Newsnote #3, Guidelines for DesigningForest Fire Engines. 1998. Gives additionaladvise for designing and planning water tankvehicles. Available in pamphlet form or online atwww.RoscommonEquipmentCenter.com.

REC Slip-On Tank Designs

REC has several publications that feature slip-on tanks with complete design details. Theseprovide design ideas for those intending tocontract for or make their own tanks.

REC Project #33, Tanker Handbook, Military 1-1/4 Ton, 4x4 Cargo Truck, includes designdetails for a 200 gallon steel slip-on unit.Available as a booklet.

REC Project #34, Tanker Handbook, Military 3/4Ton, 4x4 Cargo Truck, includes designdetails for a 150 gallon steel slip-on unit.Available as a booklet.

REC Project #40, Tanker Handbook, Military880 Series 1-1/4 Ton, 4x4 Cargo Truck(Dodge W-200), includes design details for a200 gallon steel slip-on unit. Available as abooklet.

REC Project #61B, Indiana 90 Gallon and 150Gallon Aluminum Slip-on Unit. Available on-line athttp://www.roscommonequipmentcenter.com/projects/rec61b.pdf. Includes design detailsfor two aluminum tanks; one for full size andone for mid-size pickup trucks.

Poly Tank Suppliers

The following is a list of known polymer tankmanufacturers. Listing does not constitute anendorsement. REC Project #61 has a list of

some slip-on tank suppliers for those looking fora complete pump and tank assembly.

LeVan Manufacturing, Inc.2440 SW Ferry Street, Ste. D, P.O. Box 1023, Albany,

OR 97321Telephone: (541) 924-5653 or 1-888-674-0030Web Site: www.levanmfg.com

Pro Poly of America, Inc.1821 Northwest 57ty Street, Ocala, FL 34475Telephone: (352) 629-1414Web Site: www.propolyamerica.com

United Plastic Fabricating, Inc.165 Flagship Drive, North Andover, MA 01845Telephone: 1-800-638-8265E-mail: [email protected] Site: www.unitedplastic.com

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9

Appendix B - Poly Tank Specifications

Polymer Water TankSpecifications for Part No. 23-0094

USE: The product will be used as a water tankmounted on a steel flatbed of a truck. The tankwill be used for wildfire control. The vehicle willbe operated off-road a portion of the time.

CONSTRUCTION: The tank will be constructedusing the manufacturer’s fire service gradepolymer (polypropylene orpolypropylene/polyethylene blend) material.Material on outside of tank shall be opaque,black in color, and UV resistant. Exception tothis can be made for tank bottom, hose reelmounting pads and sight gauge. The outersides and top must be 1/2 inch thick. Thebottom must be 3/4 inch thick. Internal materialfor baffles or gussets must be 3/8 inch thickminimum and can be of a suitable nonopaquematerial. Baffling must allow for adequate waterand air flow based on 125 gallon/minute pumpperformance. Welds must meet industry qualityand appearance standards

TANK DIMENSIONS: See drawing (23-0094B)for overall dimensions.

FILL TOWER: A rectangular-shaped fill towerwill be provided on the front left top of the tanknear the corner. It shall have a hinged lid, and ascreen with maximum 1/4 inch diameter holes tofilter water entering the fill port. The insideopening shall be a minimum of 45 squareinches. The inside minimum dimensions shallbe at least 6 inches. A 4 inch diametervent/overflow pipe shall be incorporated in the filltower. The drawing shows the overflow pipeoutlet location.

SUMP: The tank shall have a sump as shown inthe drawing. It shall include a 3 inch FNPTthreaded clean-out with plug. It also shall havea 3/4-inch FNPT drain with plug. Both of thesewill be on the sump bottom. A dip pipe shall runfrom the suction outlet to the sump. It’s endshall be submerged approximately 3 inchesdeep into the sump opening.

SUCTION AND FILL PORTS: The rear wall ofthe tank shall have ports placed as shown in thedrawing. The suction port shall be threaded 2-inch FNPT. The fill inlet shall be 1-1/2 inchFNPT. The fill inlet can be moved + 2 inches(left or right) to accommodate baffle placement.

TANK MOUNTING PADS: The manufacturershall provide adequate mounting pads for thepurchaser to fasten the tank by threadedfasteners to the truck bed. It is preferred to havea four point mount, with a mounting point ateach corner of the front and back tank walls.

CONTACT: It is the purchaser’s intent to allowthe manufacturer to use its normal fire tankconstruction concepts within the dimensionconstraints provided. If that cannot beaccommodated by these requirements, pleasecontact (your name and telephone number), withany proposed variance.

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12

Appendix C - Drilling Holes in Truck Frame Rails

From time to time it is necessary to mount anitem to a truck’s frame rails. The frame rails arethe most substantial mounting points available,but altering or modifying these parts should notbe taken lightly. Before drilling into the frame,check with the truck manufacturer forinformation on what is allowable. If themanufacturer says not to, don’t do it. Below aresome things you should consider.

§ Use existing holes, whenever possible. Themanufacturer puts many holes in frames forthe variety of optional items they may needto mount. Many of these will be unused.See if you can use some of these existingholes to accomplish the mounting. Often thiswill be the case.

§ Do not drill holes in the frame flanges orupper or lower part of the web withoutguidance from the truck manufacturer.Figure C-1 shows the important parts of aframe channel. The channel’s flangescontribute greatly to the strength of theframe. Weakening them by drilling holes isnot advisable, unless you have the technicalexpertise or information that says otherwise.

§ If holes are necessary, plan to drill any holesalong or near the neutral axis of the frame.Most truck frames are symmetrical top tobottom, which means that the neutral axis isthe center line of the frame (halfway downfrom the top). Figure C-1 illustrates thelocation of the neutral axis and shows twoholes located directly along it. The darkergray stripe illustrates the approximate zonein which it’s normally safe to drill.

§ Do not drill holes too close together. A 2inch minimum spacing is desirable but it iswise to check with the manufacturer for theiradvice.

§ Watch out for other components when youdrill. Brake, fuel, and electrical lines arenormally routed inside the frame rails.

Some might have the urge to weld brackets to atruck frame rail. We strongly discourage thispractice, unless you have direct consultationwith the truck manufacturer. Welding maychange the metallurgical composition andtherefore the strength of some frame railmaterials. Additionally, welded designs almostcertainly will require welds somewhere otherthan the neutral axis. Only those with the propertechnical knowledge and experience shouldattempt to weld brackets or other components tothe truck’s frame rail.

Neutral Axis

Flange

Web

Figure C-1 - Frame channel definitions.