Last month, we showed you an overview of the body-drop technique "channeling" that we used on the Weekend Warrior Toyota Cab, and we also showed the body-drop of the bed. For Part II, we're going into some detail and outlining the tubbing of the firewall and body-dropping the front frame horns. These are important steps in the process, which have not really been addressed in their own tech stories. So, follow along and see how to tub your firewall for a bigger wheel on that body-drop. For more information, contact the companies listed in the sources box.
1. We're going with 19-inch...
1. We're going with 19-inch wheels, because we body-dropped the truck past the pinch and still want a decent size tire to drive on. First, we measured how much more room we'll need for our wheel/tire combo and then we started by drilling out the spot welds for the factory tub.
2. Next, we measured again...
2. Next, we measured again and marked our cut lines. Before cutting, we recommend you make sure to clear out the fuse box and whatever else might be in the way on the other side, then cut away.
3. With the firewall cut and...
3. With the firewall cut and out of the way now, we can make our tubs. We measured the area needed to be filled, made a template, and went to town. No fancy tricks here, just a metal break for the top flat bend. Then the rest was hand-formed out of 18-guauge and tested to match the curve of the wheel.
4. Our tub was test fitted...
4. Our tub was test fitted a few times and bent little by little until it was just right.
5. Once all was lined up,...
5. Once all was lined up, the tub was tacked into place.
6. After the tub was tacked,...
6. After the tub was tacked, we checked all of the corners and final fitment to make sure it was perfect, and then it's fully welded in, slowly but surely.
7. To fill the inside gap,...
7. To fill the inside gap, a scrap piece was traced and cut.
8. Once the curve was right,...
8. Once the curve was right, it was tacked in place.
9. With the metal securely...
9. With the metal securely tacked, the outside excess was cut off with the plasma.
10. Now the outside could...
10. Now the outside could be fully welded.
11. With everything welded...
11. With everything welded up, all of the edges were ground smooth.
12. The outside needed to...
12. The outside needed to be capped, so we traced another template and built an end-cap piece.
13. The cap was then welded...
13. The cap was then welded into place.
14. And there you have it:...
14. And there you have it: plenty of room for the body-drop and some decent size wheels!
15. Apply a little seam seal...
15. Apply a little seam seal in all of the corners, then you can spray the tubs with texture or smooth paint to match the rest of the firewall.