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Old 31-07-2019, 09:33 AM   #1
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Default Tray Repairers

Asking in advance because sometimes one finds an industry is very ďclosed shopĒ.

Foster Ute has light damage to the tray rear. I believe itís an old Challenge item, probably on its third chassis. Are the extrusions really unique and proprietary, or are they typically available from the big alloy suppliers?

Or - do the tray manufacturers refuse to sell sections, desiring to keep repairs in-house?

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Old 31-07-2019, 12:15 PM   #2
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Default Re: Tray Repairers

I found a similar problem trying to repair a sectional garage door, but that was more visual.

You could get a similar profile from an Alco manufacturer, and shim it if required.

what does the top look like? is it that bad
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Old 31-07-2019, 01:23 PM   #3
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Default Re: Tray Repairers

Best to repair it rather than replace. Find a suitable aluminium alloy z-section from an aluminium supplier to use as a repair section. You'd only need a short piece say 300mm long (or more if needed, I cant really tell how far the damage extends) to nest into the existing section, extending past the damage each side. Might be even be better instead to use two right angle sections back to back each side of the existing section which will then avoid needing shims.Cut away the torn flange (leaving the remaining intact section), and bend the remaining bent part of the damaged extrusion back into shape. then Pop rivet the repair z- section in after painting the bare surfaces, say 4 rows of rivets each side past the cutout section to restore the strength.
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Old 31-07-2019, 02:04 PM   #4
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Default Re: Tray Repairers

It may yet come to a repair. The main problem is that itís a ďfinisherĒ plank with the end rail being part of the extrusion - and therefore under some pressure as the mounting place for tailgate hinges. The OEM hinges locate in a recess of the extrusion and further anchor the longitudinal rails against sideways racking.

Cutting this vertical end away and inserting a meaty U-channel would be one fix.

Glad to not hear that tray manufacturers are famous for being a law unto themselves - or anything similar.
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Old 31-07-2019, 02:19 PM   #5
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Default Re: Tray Repairers

You can buy the sections from most ally mobs. You have to remove the coaming rail along one side and slide the damaged section out and replace with the new one. Getting the right profile might be problem but I’m sure most the big mobs carry various styles. See if you can find a makers mark somewhere and ring around.

We use this mob in QLD.
http://alsun.com.au/products/transport-sections
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Old 31-07-2019, 03:00 PM   #6
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Default Re: Tray Repairers

Iíve just had an initial discussion with a chap called Peter, from Flexiglass NSW.

Have sent in requested images, will be interesting to see what comes of it.

Trawled Gumtree and Fleabay, canít find out where the damaged trays end up!
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Old 31-07-2019, 04:30 PM   #7
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Default Re: Tray Repairers

Quote:
Originally Posted by CitroŽnbender View Post
Iíve just had an initial discussion with a chap called Peter, from Flexiglass NSW.

Have sent in requested images, will be interesting to see what comes of it.

Trawled Gumtree and Fleabay, canít find out where the damaged trays end up!
I would assume all damaged trays are either repaired or gone to scrap metal.
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Old 31-07-2019, 04:55 PM   #8
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Default Re: Tray Repairers

Yes, found a couple of elephant graveyards late today via some mates. One place a scrappy, the other a truck wrecker.
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Old 31-07-2019, 08:57 PM   #9
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Default Re: Tray Repairers

Ullrich aluminium sell all the transport related profiles. https://www.ullrich.com.au/extrusions download their online catalogue. A lot of bigger old trays end up as farm trailers.
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Old 03-08-2019, 10:52 PM   #10
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Default Re: Tray Repairers

Flexiglass emailed back late on Friday; they will sell me the section if desired, itís about $150 in my hands. Yet to check out the elephant graveyards or my mateís tip-off about a scrap tray at his workplace.
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Old 21-08-2019, 07:36 PM   #11
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Default Re: Tray Repairers

Mate of a mate finally got back to me, three trays at a sound price, one is a ďTelstra boxĒ. This could be interesting! Tiny house time?
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Old 22-08-2019, 08:39 AM   #12
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Default Re: Tray Repairers

other option keep it as is, paint Telstar (old Ford name) keep those colours as close to Telstra and annoy the shoit out of your neighbours.
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Old 22-08-2019, 09:02 AM   #13
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Default Re: Tray Repairers

Most of my neighbours would find that hilarious.

Wouldnít they make a great mobile kitchen/pantry, though? Might have to get HACCP accreditation.
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Old 02-09-2019, 09:34 PM   #14
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Default Re: Tray Repairers

The quick and the dead...

“Telstra body” is an XL service body with a number of those little hatch doors secured by natty hardware. White, paint sanded ready for a repaint.

One tray went to recycling before I got there - can’t complain, illness is the luck of the draw.

The other tray was a 6x6 Planet Ute off a BT-50, too short and slightly too wide for Povo Ute - and the floor/coaming rail profiles are different. Nice clean unit, brushed stainless hinges,stainless fixings, even got lights and factory harness. I’ll try to unload it as a tray before weighing it in.

Last edited by CitroŽnbender; 02-09-2019 at 10:03 PM.
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Old 12-10-2019, 09:02 PM   #15
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Default Re: Tray Repairers

Flexiglass seem to use a fairly unique set of profiles. Their decking planks are "back to front" when compared with many, and are also pretty light on. I couldn't find a match from any commercial extrusion supplier.

My situation was resolved with matching donor planks from a lightly damaged crew cab tray that cost me six hours' work. Three planks too short to use in entirety, but I gutted it and used my "least worst" original three with these ones. Elapsed time was sixteen days, but that's on a part-time repair basis. Greatest other expense after the car's "sitting cost" of about $14/day was stainless fasteners.

From my experience, if you have a place to work and a decent drop saw with aluminium cutting blade, the only physical issue with DIY tray building or repair is the swarf. I'd build one from scratch to save the beans, if it priced up that way.
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Old 13-10-2019, 07:56 AM   #16
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Default Re: Tray Repairers

Sound like your having a few issues, I think I would have bought another second hand one to fit, but a get you don't have the space.
I know a guy doing the same with an AU ute/tray only he just adapted a steel one.
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Old 14-10-2019, 08:24 AM   #17
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Default Re: Tray Repairers

I just paid $350 for 2 mid panels and rear panel from flexiglass dealer locally which i thought wasnt too bad. You can get them in and out without removing side rails with some mucking around. Would never own another flrxiglass tray though, theyre not real strong and totally buckle at the slightest impact
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Old 15-10-2019, 07:57 PM   #18
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Default Re: Tray Repairers

That pretty much sums it up as I found too (the inherent weakness). It's all back together, my repair came in a shade under yours with standing cost included, and labour priced at nil.
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