Gas can, oil jug and sockets, fitting just right in their cubbies. Can’t leave home without them, especially not in this car!

Flashback to just after the rough cut on the C-pillars.

Took some head scratching to figure out how to keep the cut symmetric across the two sides of the car, but once again it was the construction laser to the rescue. Still, easier said than done because there were multiple layers of irregularly shaped sheetmetal to cut through, and you mark from the inside but have to cut from the outside.

With the laser sitting at the center of the rear window, I projected and marked lines as such (right rear wheel arch shown):


To “spot” the line from the outside, I drilled spotting holes some distance above the line, then measured downwards on the outside to mark discrete points. After using masking tape to link the points up smoothly, it was back to the good old cut-off wheel.

Then began the tedious process of shaping and welding the topside close off panels, stretching from the B-pillars to the back wall. Took very few pictures as I was rushing to finish before clearing out of the space on Sunday night, but this should give a sense of what was involved.


Even the tacks were pretty tricky as the panel seam wanted to open up with any application of heat. I had to fixture the panel in place with multiple strips of Kapton tape and tack between the tapes. Same deal with the smaller panel just in front of the rear wall, shown here with the inner close-off already in place:


Switching gears, I laid out the bed frame using 80/20 aluminum channel, and used diamond plate to start forming the floor of the bed. More on that in a later post. I also added another crossbeam to bring the window line up to a more suitable height.

Then cut and welded new sheetmetal to form the skin of the rear wall, which really helped my right elbow to not freeze solid when driving at night.


More close-offs at the front of the bed, next time.