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Functional Roll Back Pt. 2
Topic Started: Jan 19 2007, 06:59 PM (824 Views)
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Making The Bulkhead

The style of bulkhead is really up to you. There are many different variations out there so have fun. I built a basic square one with a window cut out. Cut one piece of the 3/16" square tubing 3" long with 45 degree angle on both ends for the top bar. Cut two pieces 1 1/2" long of 3/16" tubing with 45 degree angle on the one end of each tube for the uprights and one piece of the 3/16" tubing 2 5/8" long, square on both ends.

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Glue the uprights the top bar and the center bar 1 1/8" down from the top. You may have to trim the center bar a little to keep the bottom from kicking out.
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Next cut a piece of .030 sheet plastic 3"x 1 1/8". Layout a 1 1/2"x3/8 window in the center of the plastic.
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Cut the window out and glue it to the bulkhead as shown and sand all edges smooth and fill any gaps with putty.
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Finial Assembly And Sanding

Once the deck is dry you will need to cut two pieces of .187x.312 Rectangle. Tubing 8 1/4" long with a 45 degree angle on one end for the side boards. You can cap the ends or leave them open, it up to you.

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Next glue the side boards on the deck as shown.
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Now you can glue the bulkhead to the front of the bed. Make a mark at 3/4" for the front of the bed to locate where the bulk head goes.
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Cut 2-1/2" triangles out of .030 sheet plastic for the braces where the bulkhead meets the deck.
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Glue them in the center of the tube on the bulkhead and to the deck.
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hat completes the roll back bed.
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Continue to part 3
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