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Discussion Starter #1
Let me start off with saying that I often end up f-ing up the sides of my truck bed a good 5" down from the top of the bed rail. I am about to have a spray in bed liner installed and told the shop I wanted the liner extended about 5" down the outside and the plastic caps removed. They responded that the bed rails were full of holes and wouldnt look right so....I decided to take care of that.

I have always hated the plastic caps on these trucks and it wont be too long before I tear them up, and never have a good place to attach ratchet straps....so I opted to go overkill.
I dont recommend anyone else doing this stuff unless you have the balls, equipment and skills....but if you are feeling froggy and want to jump, here it goes.



Here are the OEM caps


The cheap caps just snap in, and heres a shot of the holes.


Started with 4.5X82X.25 mild...cost was 20$

Use the old caps as templates


Use your plasma cutter....or torch...bandsaw or jig saw (last option would suck) to cut out the form.


Used a 60 grit flap on the 7"


Remove the cutting marks with the grinder.


Measure hole placement, make sure to compensate for tool boxes. I would of moved my holes about 1" closer to the outside to avoid the clearance issues I had with the "double wall". This wasnt a problem....but did add a few more needless minutes. The rear most hole aligned with the OEM hold down hole, the others you will need to mark the bed rail and use a hole saw or plasma to allow for bottom nut clearance (below).



Purchase a few big eye bolts (*these are 15/16). I opted for 6 but 4 would work fine also. Drill holes just slightly larger then the major diameter of the threads. Screw the nut to the bolt (this will align the nut and hole), and weld it up. I used my MIG but whatever you have will do.
****just be careful you weld your nuts to the correct sides, you will have mirror R&L, if you weld them to the wrong side you nuts will be on the top of the rail and you will have a bunch of work to do to fix it.****



After you heat them up remove spatter balls and paint the underside with rust preventing paint.



Remove the paint from the lip of the rail on both sides, clamp the plates and burn them in starting with 4" spacing on low voltage (the bed is made from paper thin metal, and you will burn through). I didnt compleatly weld both sides opting for about 1" weld spacing both sides....it should be well enough to pick the truck up with the eye bolts. Make sure you use welding paper or other method to protect the paint from spatter.



Here are the rails with the bolts installed. They easily unscrew when not being used.

This isnt complete at this stage. I simply got tired of f-ing with it and didnt have any body filler I will use to fill the gap made from the lip on the plastic cap and the flat plate.

Once the bed liner is sprayed, you wont see a transition.

~JH
 

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>> I dont recommend anyone else doing this stuff unless you have the balls<<
>> just be careful you weld your nuts<<

Looks to be functional, for your needs. I do detect potential testicle difficulties though :D
 

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You sure personalized your truck! Great job making it useful for your needs. Can't wait to see it finished.
 

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And everyone said I had balls for drilling holes in my roof for cab lights..... You got me here, I definately don't have the balls to do that!

Nice mod, I'm sure it will look real good after the liner gets sprayed.
 

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I like the heavy duty bed rail. However, I don't like the eye bolts. Have you considered these tie downs?
8 Piece Track & Tie Down Anchor Kit - The kit includes (4) four anchor stud ring fittings and (4) 3 foot long rails. (Bolts for mounting the rails to a pick up truck or trailer are not included) - 2,000 lb working load per rail

Cargo Tie Down Rails & Stud Rings From Discount Ramps.Com
I used to be a aircraft loadmaster and we had this stuff on the air plane. It worked well.
The only reason that my truck does not have this tie down yet, is my daughter may get my truck.
 

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wow. to each his own. u sure made a work truck out of that hahaha and now its gonna have bedliner sprayed down the outside of the bed...interesting....but whatever works for you....
 

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Can't see the pics
 

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Can't see the pics
stop looking at it at work....:) my work filters block them too. i had to look at them on my phone. but they are there.
 

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Discussion Starter #11


After scuffing the paint and hitting it with a tack cloth I applied the first layer of Pepto to flush the plate with the bed. It will have a zero transition between the top of the bed rail and the bed side.



Here you can see the Pepto is feathering out. Its only about 1-1.5" from the top. The liner will extend 4ish inches.



You can almost see how the sides of the bed will contour to the top. In truth this will look really cool if you were to color key the tops of the bed rails to the body....you could sure get away with less then .25 plate!


I only have to fill a few low spots and its off to the bed liner place tomorrow!

~JH
 

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You are definitely a lot handier than I am with regards to mods on trucks. Can't wait to see it finished.
 

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stop looking at it at work....:) my work filters block them too. i had to look at them on my phone. but they are there.
Thats what I thought, but I've always seen everything else. I can see one of the pics but the rest have the red X. Usually if its blocked because I'm at work I get the ACCESS DENIED message.

No biggie.....:cool:
 

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What are you hauling all the time that you need to do this? I went for the much more subtle approach and followed the old thread that used the eyebolts into the rail bolt holes. they are rated 450 lbs each so will hold anything most would ever put into their truck. Way cheaper and easier to do.
And I have a cap so could not do it this way for that.
 

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Didn't realize the Tundra had a snap-on rail cover... with holes underneath. Not sure how I feel about that.
Um, what's wrong with it? It protects the bed railings from getting scratched when setting stuff on the edges.
 

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Will the bed liner stick to the filler puddy? It looks like it will be real nice, I just hope the liner doesn't lift on you.
 
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