Thickness of steel required for ute tray cage

**Corgan** · 24th March 2012, 07:36 PM

Hi guys,

did a brief search and didn't turn up much so i'll make a thread.

I've recently purchased an '06 alloy tray falcon, and the fitting out is set to commence

It currently has mounting plates for a rear ladder rack and it has an inbuilt front rack that's build into the tray (triple M tray)

I plan on putting some mounting plates up the front of the tray, as far forward as it'll go, and making a 3 walled cage. more specifically, i plan on using the ladder rack mounts to bolt 2 inverted U shaped frames along each side, and attaching a hinged rear gate to close up the cage.

couple of questions for those with experience;

for the mounting hardware up front, i plan on using some 3mm galvanised builders brackets- bolting directly to the tray and also to the headboard of the tray at the front. i plan on putting plates either side of both bolts. some square tube will be welded to these brackets, with a hole and a nut welded on so the cage components can slot into the tube and get bolted in place. sound alright?

secondly, what would you suggest as the minimum thickness of the actual cage tubing (square tube)? I wish to make it out of 304 stainless, i know its a bit more expensive but i love the stuff, lol. any structural reasons not to?

thanks in advance and let me know if i've been confusing in my description

**racingtadpole** · 25th March 2012, 05:11 PM

If it were me, I'd be using Galv SHS or RHS not Stainless (WAY!!! cheaper, and easier to source). 25x25x1.6 will be plenty strong enough for that application, or if you can weld thin tube 38x20x1.2 Galv RHS (common fence rail size) would do the job too.

**Corgan** · 26th March 2012, 07:20 PM

thanks mate- given the size of the mounting hardware already in place, i'll be using 38x38x1.6 304 tubing for the job.

being that i use alot of stainless tube i have a fair few odd lengths around, so i'd happily use that for the cage instead of buying the full amount required in gal tube

cheers
corgan

**Yonnee** · 27th March 2012, 05:52 PM

No structural reason not to use Stainless. Just be aware of attaching the cage sides to the frame. I've seen many a nice bow in the length of a tube after the mesh has been welded in from one end to the other...

**Corgan** · 27th March 2012, 07:56 PM

Fair call yonnee- I'm well used to dealing with distortion. Tig and slowly, I should be fine. Hopefully get most of the work done this week, I'll post it up

**Karl Robbers** · 27th March 2012, 08:56 PM

Originally Posted by Corgan

Fair call yonnee- I'm well used to dealing with distortion. Tig and slowly, I should be fine. Hopefully get most of the work done this week, I'll post it up

With the number of welds required to hold the mesh it will still distort no matter how you weld it, tig, mig or otherwise.
I do like the idea of SS for the frame though, it will maintain it's appearance beautifully over the years.
I would use SS plates to mount rather than the galv builders brackets though.

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