Looks good. Can you give a few more details about the process. I have a 1983 F150 that I'm think about cutting up. Any bracing or anything, any tips, advice, pointers, etc.
Thank you. I took my time with it, because i didn't want to mess anything up. It was about 9 or so hours doing it all. I really took my time lol. I marked the hole in the bed.
I cut it with a cutting wheel. I made the corners round, with the radius of a cutting wheel. I cut the corners with a jigsaw. On the inside, the top 2 corners, i couldn't cut them with a jigsaw. So i cut and angle on it, and grounded the radius out with a cutting wheel.
I used accordion boot to seal the cab/bed. One site had it for $6/ft, another had it for $73 for 15ft, i bought the 15ft roll. I put caulking on the metal, and then put on the boot. The bottom metal was almost corrugated, but it went on that fairly well.
I glued waterproof padding strips to the front lips of the box(i had the sub panel 3" deep). After that i put caulking around the edges.
Then i pushed the box tight against the bed, and used L brackets to secure it. 1 on each side, and one on the back.
I figured my window would flex like crazy, so i got a piece of 3/8"x2" steel, the width of my window, and bolted it to the metal below my window. I would say it helps, but it still flexes a lot.