Tray Repairers

[Citroënbender]

Asking in advance because sometimes one finds an industry is very “closed shop”.

Foster Ute has light damage to the tray rear. I believe it’s an old Challenge item, probably on its third chassis. Are the extrusions really unique and proprietary, or are they typically available from the big alloy suppliers?

Or - do the tray manufacturers refuse to sell sections, desiring to keep repairs in-house?

[Vesper Martini]

I found a similar problem trying to repair a sectional garage door, but that was more visual.

You could get a similar profile from an Alco manufacturer, and shim it if required.

what does the top look like? is it that bad

[Silver Ghia]

Best to repair it rather than replace. Find a suitable aluminium alloy z-section from an aluminium supplier to use as a repair section. You'd only need a short piece say 300mm long (or more if needed, I cant really tell how far the damage extends) to nest into the existing section, extending past the damage each side. Might be even be better instead to use two right angle sections back to back each side of the existing section which will then avoid needing shims.Cut away the torn flange (leaving the remaining intact section), and bend the remaining bent part of the damaged extrusion back into shape. then Pop rivet the repair z- section in after painting the bare surfaces, say 4 rows of rivets each side past the cutout section to restore the strength.

[Citroënbender]

It may yet come to a repair. The main problem is that it’s a “finisher” plank with the end rail being part of the extrusion - and therefore under some pressure as the mounting place for tailgate hinges. The OEM hinges locate in a recess of the extrusion and further anchor the longitudinal rails against sideways racking.

Cutting this vertical end away and inserting a meaty U-channel would be one fix.

Glad to not hear that tray manufacturers are famous for being a law unto themselves - or anything similar.

[73 4V XB]

You can buy the sections from most ally mobs. You have to remove the coaming rail along one side and slide the damaged section out and replace with the new one. Getting the right profile might be problem but I’m sure most the big mobs carry various styles. See if you can find a makers mark somewhere and ring around.

We use this mob in QLD.
http://alsun.com.au/products/transport-sections

[Citroënbender]

I’ve just had an initial discussion with a chap called Peter, from Flexiglass NSW.

Have sent in requested images, will be interesting to see what comes of it.

Trawled Gumtree and Fleabay, can’t find out where the damaged trays end up!

[73 4V XB]

Originally Posted by Citroënbender

I’ve just had an initial discussion with a chap called Peter, from Flexiglass NSW.

Have sent in requested images, will be interesting to see what comes of it.

Trawled Gumtree and Fleabay, can’t find out where the damaged trays end up!

I would assume all damaged trays are either repaired or gone to scrap metal.

[Citroënbender]

Yes, found a couple of elephant graveyards late today via some mates. One place a scrappy, the other a truck wrecker.

[roKWiz]

Ullrich aluminium sell all the transport related profiles. https://www.ullrich.com.au/extrusions download their online catalogue. A lot of bigger old trays end up as farm trailers.

[Citroënbender]

Flexiglass emailed back late on Friday; they will sell me the section if desired, it’s about $150 in my hands. Yet to check out the elephant graveyards or my mate’s tip-off about a scrap tray at his workplace.

[Citroënbender]

Mate of a mate finally got back to me, three trays at a sound price, one is a “Telstra box”. This could be interesting! Tiny house time?

[Tonz]

other option keep it as is, paint Telstar (old Ford name) keep those colours as close to Telstra and annoy the shoit out of your neighbours.

[Citroënbender]

Most of my neighbours would find that hilarious.

Wouldn’t they make a great mobile kitchen/pantry, though? Might have to get HACCP accreditation.

[Citroënbender]

The quick and the dead...

“Telstra body” is an XL service body with a number of those little hatch doors secured by natty hardware. White, paint sanded ready for a repaint.

One tray went to recycling before I got there - can’t complain, illness is the luck of the draw.

The other tray was a 6x6 Planet Ute off a BT-50, too short and slightly too wide for Povo Ute - and the floor/coaming rail profiles are different. Nice clean unit, brushed stainless hinges,stainless fixings, even got lights and factory harness. I’ll try to unload it as a tray before weighing it in.

[Citroënbender]

Flexiglass seem to use a fairly unique set of profiles. Their decking planks are "back to front" when compared with many, and are also pretty light on. I couldn't find a match from any commercial extrusion supplier.

My situation was resolved with matching donor planks from a lightly damaged crew cab tray that cost me six hours' work. Three planks too short to use in entirety, but I gutted it and used my "least worst" original three with these ones. Elapsed time was sixteen days, but that's on a part-time repair basis. Greatest other expense after the car's "sitting cost" of about $14/day was stainless fasteners.

From my experience, if you have a place to work and a decent drop saw with aluminium cutting blade, the only physical issue with DIY tray building or repair is the swarf. I'd build one from scratch to save the beans, if it priced up that way.

[roKWiz]

Sound like your having a few issues, I think I would have bought another second hand one to fit, but a get you don't have the space.
I know a guy doing the same with an AU ute/tray only he just adapted a steel one.

[Jack91]

I just paid $350 for 2 mid panels and rear panel from flexiglass dealer locally which i thought wasnt too bad. You can get them in and out without removing side rails with some mucking around. Would never own another flrxiglass tray though, theyre not real strong and totally buckle at the slightest impact

[Citroënbender]

That pretty much sums it up as I found too (the inherent weakness). It's all back together, my repair came in a shade under yours with standing cost included, and labour priced at nil.