The OCD Truck Bed Ski Hauler Deck/Tonneau Build

OCD Solutions

Original, Clean and Dependable Solutions
Location
Rentz, GA
It's still not 100% completed but it's finally to a stage where I don't mind sharing pics.

FYI, this was a personal project and not something that I have any plans of offering for sale so there's no official product release or price tag. It was custom built to fit my 2003 Dodge Ram and so the dimensions are somewhat specific.

Construction is all 6061 aluminum. Weight is 133lbs for the deck and 30lbs per bunk. The bunks are removable so when not in use hauling skis, it looks clean and OCD. Unlike most tonneau covers, this one has a 750lb payload capacity and durable deck so there's no need to remove it. If you have to haul something too large to fit under it, just throw it up on top and strap it down.

It started out as a simple scaled down sled deck but after using an ARE Tonneau for the past 3 years, I really wanted it to flip up. Even though that option came with compromises, an increase in complexity and overall cost, the results were worth it.

Care was taken to ensure the skis would be as far forward as possible but yet still allow a safe distance from the rear window, as well as the option of still being able to lift the lid, even with the ski bunks in place.

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Here'a s little vid of the first load.

 
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OCD Solutions

Original, Clean and Dependable Solutions
Location
Rentz, GA
In order to allow the deck to flip up, I had to build a set of pivot bushings. This was a great test of my CNC skills and I was able to make multiples on my lathe and maintain .003" tolerance between all parts.

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Did I mention that it comes with gadgets?

The skis are pulled up on top via dedicated Warn XT15 winches. Each winch is wired on it's own circuit all the way back to the battery and controlled by their own wireless remote so there's no waiting, both skis can be loaded at the same time if you really need to get loaded up fast.

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I opted for the synthetic winch line because I hate getting strands of wire in my hands. Stress testing shows it's plenty strong enough for this task...

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In order to facilitate secure, under deck storage, I had originally installed a locking tailgate handle but it was junk so I purchased a power tailgate lock from Pop & Lock that works with the factory keyless entry. $95 on sale and installs in around an hour.

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OCD Solutions

Original, Clean and Dependable Solutions
Location
Rentz, GA
The rollerized deck and remote winches were not in the original plan but a buddy challenged me to built it so he could load and offload with one hand.

He is a fellow rider that was involved in a motorcycle accident a couple years ago that left him with many injuries and limitations. He can ride still but his biggest struggle is loading and unloading at home.

I opted for roller blade wheels mostly because they were cheap and it was a bit of an experiment. I went with a common size so they are easily upgradeable should I find it necessary to upgrade to something more durable.

Each wheel pocket was machined out on my CNC mill rather than bolt them to the side like other systems do.

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The removable bunks are attached via a slotted retainer system, also machined in house.

Here's some mock ups from writing the code to cut the patterns.

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OCD Solutions

Original, Clean and Dependable Solutions
Location
Rentz, GA
Placeholder for future ramp pics and loading video.

The winches will pull the skis off the cart now but I still have to build a short rollerized ramp to help get them over the hump and take the strain off the winches. It'll do in a pinch but it's not near OCD enough yet.

The project has been a steady drain on my account so progress has been slow as OCD cash allows. Instead of planning everything out and building all at once, I have approached this one step at a time and then tested to see what I can get away with for the next step. WI waited until the ramps and deck were completed and then mocked it up to see what was actually needed to load from a beach cart. Turns out a short and simple design will work just fine rather than the full length one I originally had in mind.

....but ramps will follow soon...and then maybe a video or two....and maybe a few other additions...

Here's a pic from one of the first test runs to see what angles I was dealing with...

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Teaser pic of an upcoming project...IMG_7844.JPG
 
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OCD Solutions

Original, Clean and Dependable Solutions
Location
Rentz, GA
I wasn't gonna polish it much further, was going for a brushed look, but then this sumbitch had to go ahead and post this video....

Now i gotta do it right!?!?!?!?!

:mad::mad::mad::mad::mad::mad::mad:

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