Sled deck build project...

[DangerousDave]

There are lots of great sled decks out there, but I just like to build my own stuff. Here's my latest project, a custom year round deck to be used for work and recreation.

Here's a list of wants and needs.

1) Must look nice on the truck, like it's suppose to be there.
2) Must be robust, mounted to bed floor no damage to the truck.
3) Must allow bed rails to flex, but be sealed for dry storage
4) Concealed side extensions.
5) Needs to be able to haul 2 sleds or a side by side and still allow to pull a travel trailer.
6) Needs to be able to easily convert from sled deck use to accept a ladder / pipe rack (that doubles as a boat rack)
7) Slide out under deck storage for tools, gear, tailgating, large enough to carry 4x8 sheets
8) Telescoping ramp storage that slides ramp back far enough to hook right on the deck without having to wrestle with the ramp.
9) All aluminum, no wood on deck or under feet in bed.

Here are some pics of the progress so far.
I'd welcome any suggestions or critiques.

 

[warreng417]

There are lots of great sled decks out there, but I just like to build my own stuff. Here's my latest project, a custom year round deck to be used for work and recreation.

Here's a list of wants and needs.

1) Must look nice on the truck, like it's suppose to be there.
2) Must be robust, mounted to bed floor no damage to the truck.
3) Must allow bed rails to flex, but be sealed for dry storage
4) Concealed side extensions.
5) Needs to be able to haul 2 sleds or a side by side and still allow to pull a travel trailer.
6) Needs to be able to easily convert from sled deck use to accept a ladder / pipe rack (that doubles as a boat rack)
7) Slide out under deck storage for tools, gear, tailgating, large enough to carry 4x8 sheets
8) Telescoping ramp storage that slides ramp back far enough to hook right on the deck without having to wrestle with the ramp.
9) All aluminum, no wood on deck or under feet in bed.

Here are some pics of the progress so far.
I'd welcome any suggestions or critiques.

Lookin good, Any more progress? What is the alum decking from? Looks like the stuff seen on marine docks.

 

[DangerousDave]

The aluminum decking was salvaged out of a delivery truck that flipped on its side last year in the snow.

I made a little progress today, welded the headache rack on. (The headache rack was a craigslist find)
Put the deck on the truck so I could layout the front of the side rails to match up with the bed and blend into the cab.
Made gaskets to seal it to the bed rails.
Bolted the super tracks to the outside of the extensions.
It's not ready to haul sleds yet but it's going to make a trip to Halfway Oregon later this week (I'm trailering the sleds)
In the pictures you can see the 4 reciever tubes, one in each corner to accept ladder racks, boat rack, and there will be an extension that drops in the back 2 to support the Sleds, SXS and the ramp.
I tried to maximize the under bed storage, you can see the channels that the bearings will ride in for a 4x8 slide out tray.
I'm thinking about covering the entire deck with Superglides.
Once it's done all the exposed aluminum will be polished.

 

[DangerousDave]

I’ve made a little more progress...

I built a piece that drops in to the rear receiver tubes when hauling sleds or the polaris ranger. It has a 2” tube on the back that the ramp will hook to. It also has a square tube farther forward that is spaced so the snowmobile track will straddle both tubes AND it’s laid out so the rear tires of the ranger drop between the 2 tubes.

I also started laying out the ramp. It will be 53” wide 11’ telescoping ramp with superglide “wide slides”. The bars that the track climbs up are 1 1/4” square tube spaced 14 5/16” apart. This spacing will allow a 2.86” pitch track to climb up the ramp without the lugs rolling over some of the bars.

 

[hughesfoundation]

Where did you get the supertracs material for the outside of the bed?

 

[DangerousDave]

Where did you get the supertracs material for the outside of the bed?

I ordered the “L Track” airline track and a bunch of fitting attachments from USCC (US Cargo control)

I incorporated a 45 deg angle into the sides to keep the pull angle straight when using tie downs.

 

[hughesfoundation]

Thanks, great source. Can you post closeup of how you did the 45?

 

[rhino89523]

DAM!!!! I can see with your skills why you like to build your own stuff. I have never seen a sled deck that appeared to be so much a part of the truck or that you would want to leave on year round. Your Ideas are killer. I have zero suggestions, that is a well thought out and executed project. Bravo!!!

 

[DangerousDave]

Thanks, great source. Can you post closeup of how you did the 45?

Here’s a couple photos, one of the sketch when I was laying it out and one of how it turned out. I made the angle of the 2 1/2” outside rail match the angle of the truck cab then welded a 1 1/4” bar at an angle to give it some rigidity. I bolted the L Track on with stainless Allen head countersink bolts.
After further review it’s a bit less than 45 deg.

 

[High Voltage]

Very good job!

 

[Blueside]

Any finished pictures with sleds on it? Looks killer!

 

[thesledhead]

Wow! Very nice.