Building an ALUMINUM Flatbed for my Project Truck!

I build an aluminum flatbed for my Duramax project truck with help from @ZILAwelds .

[jameskyser]

33:09 that was not the welder making that noise Waldo 😳

[asbjrnkvisle]

Maybe I said it before, but it's great that you include measurements for metric. For us that don't use thumbs and feet and other body parts for measuring 😄

[SteveP-vmuc]

Another great video, Waldo. I have a few suggestions for you. 1). try to run all your wiring inside of the tubes with that plastic spiral sheathing. 2) Add a couple spot lights to the headache rack. Hooking up trailers and strapping things down and checking straps at night can be a rough deal without great lighting. 3) Everywhere you run wire/wire looms through the aluminum use a grommet with silicone calk in the grommet channel. This will help keep the grommet in place and keep the hole you drilled for it from corrosion. 4) Once you know exactly where the fuel tank/tool box is going, add gussets to the headache rack. They will save you in the long run... 5) Wire in a few lights and switches for wheel well lighting. I used to haul cars cross country. I've had a few flats and other issues in some pretty dark places where well lights would have saved my ass in a big way.. 6) Emergency flashers are one thing, but strobe lights are a far cry better.. People know what is what for miles before a hazzard flasher.. Day or night!!!

[pedrogonzalez.]

Hey Waldo, here is another viewer who is very grateful for the metric measurements, that makes it much easier to size the pieces or thicknesses. Looking forward for the next video. Be safe, much love from Chile 🇨🇱 !

[kentmckean]

6:34 Nice door!!! Next project should really be a new door for the workshop.

[scottkakos]

Looks great so far. I have lots of flat beds and I would like to mention one thing that would give a lot of strength to the headache rack. It needs to be gusseted to the bed or it will break the welds as they tend to shake back and forth.

[kearnsey]

Waldo, immense respect for your talent! Great work! Love your content!

[lunchbox]

Looks sharp. Nice job. You have great fabrication skills.

A little advice:

Although aluminum is strong, it is very prone to cracking (especially when it is in a high-vibration service life, such as a vehicle).

Aluminum does rust, it’s in the form of aluminum oxide. This oxide layer gives aluminum anti-corrosion properties. You should remove the oxide before welding as it will contaminate the weld with hydrogen (which can cause cracking, especially on 6061). This oxide layer also melts at 3-times the temperature as the aluminum itself, so it makes welding easier to remove the oxide prior to welding.

Wire brush the weld joints with a stainless wire brush to remove the oxide and clean all oil and chemicals off with acetone or isopropyl alcohol prior to welding. Do not use a grinder or saw that has been used on plain carbon steel. Cross contamination can cause weld defects and/or cracking.

Fill your craters at the end of each weld. Craters can crack.

Aluminum does corrode when it comes in contact with certain elements. It can react with plain carbon steel (the reaction is called electrolysis). The nylon washer between the chassis and aluminum frame is a good move, but it would be wise to swap out your grade 5 or 8 steel washers and fasteners with stainless steel washers and fasteners.

Welding 6061 aluminum with 5XXX-series filler wire is generally stronger, although most welders prefer the ease and look of 4XXX-series wire.

6061 can be annealed prior to welding and heat treated after welding for some increased strength characteristics.

Hope this helps you and anyone else welding aluminum in the future.

Again, very nice work. That’s a better fabrication job than a lot of the “professional” fabricators I’ve worked with. Can’t wait for the next video.

[cameronchrestman]

Retired truck driver here ya might check into renting a truck from hertz or see if your local driving school has a short course another option is going over the road with someone who is willing to teach you

[patrickamcguire]

When cutting aluminum with a power saw, there is a candle like stick of lubricant that you use on the blade

[petersipp]

I made a new flat bed for my '65F100. I used 6061 alum. Used 4"x2" channels on top of the steel truck frame. Used 2"x2" alum angles bolted to truck frame (three per side) that bolted to the 4"x2" channel. Next... 3"x2" channels bolted to the 4"x2" crossmembers. I then had a 1/4" alum. plate (28"x 72" ) that went behind the cab (on top of the cross members). Then had 3 pieces of 5/8"x 9" A-36 plates cut for the sides & back. In the opening that was caused by the 1/4" alum in the front, the two sides & the back...I had a piece of 1/4" A-36 plate cut to fill in the opening. About 52" sq. as I remember.
I wanted to lighten the fab table up. So, using 1/4" plate was the ticket. Welded the three sides to the 1/4" plate. Doing so there was minimum warping. Can bend 1/4"x3" flat bar into a 90. I clamp the piece down very well. Wear ear protection, to form the part.
Nearly forgot...made a rack so cutting bottles could be brought along when needed.
I am pleased with how it turned out. It serves me well.

[shazils]

Waldo my man you are one of my favourite people to watch on YouTube. Every time you share your videos I get excited like A kid in a candy store.
After watching your videos I got me a mug/tig welder. You inspire me to work on my own trucks and do it the way I want it to look. Thank you for sharing with us. As always really enjoy your wonderful work. Much love from Vancouver 🇨🇦

[cameronnerdin]

PETER ZILA IS THE MAN! He is one of the finest teachers on welding skills and how to use your new welder.

[roundsm]

I started out as a commercial mechanic, I then did drive for a bit. My class A has been the most valuable thing I’ve kept over the years professionally and personally. Unfortunately I’m across the country or I’d be more than willing to help you out. Having as few restrictions as possible is definitely helpful. Good luck, Waldo!

[williamdalbey]

Waldo, you never disappoint. I am definitely one of your "needy" video groupies. ;-) I very much look forward to your future videos

[xGSFxGoat]

Great video, touched on a lot of what makes aluminum welding different than welding carbon steel. The trickiest thing I have found with welding Aluminum is how well it conducts heat: you can start a weld with one power setting and end it with a fraction of what you started because of just how much heat transfer takes place between the just-cooled filler and the rest of the workpiece.
Also, good thinking using the nylon washers between the steel truck frame and the aluminum flatbed 👍

[nospin]

Knowing when you think the viewer has scene enough of one thing and using time lapse is essential to a successful channel, your editing was spot on, kept me interested.

[mtstewart]

I remember some of your early more mechanical videos and wondering if you were going to survive with all of your digits intact, lol.
I have to say, as your channel has progressed, I believe you are unafraid of taking on, most any project that would be beyond most people, no matter how talented they might be.
The combination of your demeanor, resourcefulness and thoughtful planning, coupled with your respect for the nature of what you are doing, safety and ability to correct for mistakes make you one of the best youtube artisans, that I follow.

Never uppity or "I know best", always humble and apparantly willing to learn and grow along with leading us, to do the same with you!

I hope that you document and copywrite your material and produce it in some manner for future generations of hobbyists to industrialists for their productions? You are building valuable prototypes that many can learn from, use for templates and fashion their own skills from!
I hope you continue to find useful projects that are relevant to the hobbyist, hauler, farmer and most everyone.

Thank you, sir!

When are you breaking ground for the ultimate mechanical/weldshop?

[richardguse]

Exceptional project from so many aspects. Separate turn signal and brakes lights are very useful and should be the rule.

[richardfuerst]

When you a "special guest", you got the best!