how to build your own bed 2008 heavy duty truck rally 1 2008 hdt rally. october 4 - 11. hutchinson,...
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![Page 1: HOW TO BUILD YOUR OWN BED 2008 Heavy Duty Truck Rally 1 2008 HDT Rally. October 4 - 11. Hutchinson, KS](https://reader034.vdocuments.mx/reader034/viewer/2022051401/5697bfdb1a28abf838cb05ec/html5/thumbnails/1.jpg)
HOW TO BUILD YOUR OWN BED
2008 Heavy Duty Truck Rally
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
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How To Build Your Own Bed
Design Considerations Load Balance Features Structure
Fabrication Ready Made Components One-Off Components
Lessons Learned David Czetli Henry Szymt
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
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Load Balance
Single Most Important Consideration is…
What are the axle weights on the finished product? With the trailer hooked up? Running Bobtail?
Step 1: Weigh the truck with a full load of fuelStep 2: Determine what you want for target weight
Excel Tool Available on RVNomad.com in the tools section
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
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Load Balance
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Load Balance – The Math5
2008 HDT Rally . October 4 - 11 . Hutchinson, KS
The product of force, distance pairs on a lever are equal.Forces on opposite sides of a fulcrum are in opposite directions.Forces on the same side of a fulcrum are in the same direction.Most of the time, we are solving for one of the forces.So, if we are solving for f1, f1 = (f2 * d2) / d1
f1 * d1 = f2 * d2
d2
d1
f1
f2
f1 * d1 = f2 * d2f1
d2
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Load Balance – The Math
Pin
Rear Axle
Trailer Axle
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
GCVW = Front Axle + Rear Axle + Trailer AxleGVWTruck = Front Axle + Rear AxleGVWTrailer = Pin + Trailer AxlePin is weight is transferred to the Front Axle and Rear Axle
Front Axle
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Rear Axle is the FulcrumPin * Setback = fpin * Wheelbasefpin = (Pin * Setback) / WheelbaseLFAW = UFAW - fpin
LRAW = URAW + Pin + fpin
GVW = LFAW + LRAW = UFAW + URAW + Pin
Load Balance – The Math - Pin
Pin
Front Axle
Rear Axle
Trailer Axle
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
Wheelbase
Setback
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Front Axle is the fulcrumfDrom = (Drom Weight * DromSB) / WheelbasefBed = (Bed Weight * BedSB) / WheelbasefHitch = (Hitch Weight * HitchSB) / WheelbaseRAWToter = URAW + fDrom + fBed + fHitch
Load Balance – The Math – Rear Axle
Front Axle
Rear Axle
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
Drom Box Bed Hitch
Wheelbase
HitchSBDromSB
BedSB
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Rear Axle is the fulcrumfDrom = (Drom Weight *(Wheelbase – DromSB)) / WheelbasefBed = (Bed Weight * (Wheelbase – BedSB)) / WheelbasefHitch = (Hitch Weight * (HitchSB – Wheelbase)) / WheelbaseFAWToter = UFAW + fDrom + fBed – fHitch
Load Balance – The Math – Front Axle9
2008 HDT Rally . October 4 - 11 . Hutchinson, KS
Front Axle
Rear Axle
Drom Box Bed Hitch
Wheelbase
HitchSBDromSB
BedSB
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fBed = (2500 * 70) / 200 = 875fBike = (1200 * 100)/ 200 = 600fHitch = (600 * 50)/ 200 = 150
Load Balance – Example 1
9750 7100
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
Bike1200 lbs
Bed Load2500 lbs
Hitch600 lbs
0” 100”
130”
200”
250”
fBed = (2500 * 130) / 200 = 1625
fBike = (1200 * 100)/ 200 = 600
fHitch = (600 * 250)/ 200 = 750RAW = 7100 + 1625 +600 + 750 = 10075
FAW = 9750 + 875 + 600 – 150 = 11075
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fBed = (1800 * 80) / 240 = 600fDrom = (3200 * 120)/ 240 = 1600fHitch = (540 * 60/ 240 = 135fBumper = (2880 * 90)/240 = 1080
Load Balance – Example 2
10250
7100
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2008 HDT Rally . October 4 - 11 . Hutchinson, KS
Drom3200 lbs
Bed1600 lbs
Hitch540 lbs
0” 120”
160”
240”
300”
fBed = (1800 * 160) / 240 = 1200fDrom = (3200 * 120)/ 240 =
1600fHitch = (540 * 300)/ 240 = 675fBumper = (2880 * 330)/240 =
3960RAW = 7100 + 1200 + 1600 + 675 = 10575FAW = 10250 + 600 + 1600 – 135 = 12315
330”
Bumper2880 lbs
RAW = 7100 + 1200 + 1600 + 675 + 3960 = 14535
FAW = 10250 + 600 + 1600 – 135 – 1080 = 11235
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Calculate Max Pin Weight
10250
7100
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Drom3200 lbs
Bed1600 lbs
Hitch540 lbs
0” 120”
160”
240”
300”
330”
Bumper2880 lbs
RAW = 14535, GAWR = 19900FAW = 11235, GAWR = 12350
Available axle weight is 19900 – 14535 = 5365
f1 * d1 = f2 * d2
f1 * 300 = 5365 * 240f1 = (5365 * 240)/300f1 = 4292Assuming 20%-25%, Trailer Max is 17168-
21460
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Calculate Result on Front Axle
10250
7100
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Drom3200 lbs
Bed1600 lbs
Hitch540 lbs
0” 120”
160”
240”
300”
330”
Bumper2880 lbs
RAW = 14535, GAWR = 19900FAW = 11235, GAWR = 12350Pin = 4292
f1 * d1 = f2 * d2
f1 * 240 = 4292 * 60f1 = (4292 * 60) / 240f1 = 1073FAWLoadedToter = 11235 – 1073 =
10162
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Prove using scale tickets
10840
9340
98201688
0
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Pin5560 lbs
0” 194”
???”
f1 * d1 = f2 * d2
f1 = 5560, d1 = ???f2 = 7060 (16880-9820), d2 = 194
d1 = (f2 * d2) / f1
d1 = (7060 * 194) / 5560d1 = 246, 52” behind the axle
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Design Considerations
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What Features Do You Want?
2008 HDT Rally . October 4 - 11 . Hutchinson, KS
16Bed
Carry Stuff? Add Weight?
Drom Box Tool Storage? Satellite Dish Storage? RC Helicopters?
Support for 5th WheelStandalone Motorhome
Storage Boxes Special Items – Cookery Concert Organ with
Footboard MIG Welder w/ Tank
Smart Car LoaderExtended Boondocking
Hitch ET, ET TSR TrailerSaver BRP Head?
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Major Design Considerations
What wheelbase do you need? Single or Dual? If single, front, rear, some other?
Where do you place the hitch
What total length can you live with?
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Secondary Design Considerations
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Mounting Techniques Direct Bolt On Brackets Isolation Bushings
Miscellaneous Access to Fuel Fillers Departure Angle Clearance Rear Flat Tire Cab Shocks and Air Bags DOT Lights and Reflectors
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Secondary Design Considerations
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One Piece Installation and Removal requires heavy equipment Minimizes storage box panels Access to mounting points is difficult Access to repair items is more difficult, adds $$$ to repair
Modular Allows for manual installation of parts. More labor during fabrication. Flexible structure Removal of parts for repairs possible More difficult final assembly
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Design Consideration – Singling
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0” 80”36” 126”
Singling to the rear position transfers weight from the rear axle to the front axle.In our example above: 678 lbs.
Cab
Trans
Fuel
252”
196”
fTrans = (2500*(196-36))/196 = 2041
fCab = (3000*(196-80))/196 = 1776
fStorage = (400*(196-104))/196 = 188
fFuel = (1800*(196-126))/196 = 643
104”
Storage
fTrans = (2500*(252-36))/252 = 2143
fCab = (3000*(252-80))/252 = 2048
fStorage = (400*(252-104))/252 = 235
fFuel = (1800*(252-126))/252 = 900
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Design Considerations - Hitch
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Hitch (Applies to All Mfg) Must be directly mounted to the truck frame. Hitch Height needs to match trailer. Usually needs to be mounted below the top flange of the
frame.
Mounting Plate Must be ½” full plate OR two pieces of 6” wide, ¾” plate.
Source - TrailerSaver mounting instructions No drilling in frame flanges, only in the frame web. No welding on frame in front of rearmost suspension
mount point.
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Hitch Placement
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Hitch placement affects: Loaded axle weight Turning Capability
Jack Knife Campground backing Urban maneuverability
Deck Utilization
Hitch placement may require structural truck work Air bag valve actuator arm Frame cross members
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Hitch Placement – Avoid Jack Knife
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Design Considerations - Hitch
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Protuberance
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Hitch Placement – Calculate Arc
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The distance from the furthest point is given by the Pythagorean equation.A2+B2=C2 , A=16.5, B=51, therefore C=56.1
Always use 51 for “B”
Height of Protuberance
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Hitch Placement – Account For Dip
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As the trailer and truck move off-angle, the cap of the trailer moves towardsthe truck as specified by Sin 10o * Height of Protuberance.
5o is trucking standard minimum. 10o covers just about every campground.
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Hitch Placement – Useable Deck Space
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Usable deck space is the area tangent to the Arc at it’s midpoint.
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Hitch Placement – Typical Installation
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DOT and Your Bed
Do you need a DOT sticker ?
NO, But …
What do they actually care about ?
Safety Equipment
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What’s Wrong?
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No Reflector on outermost corner