Fixing and modifying electric pole rack on truck.

In this video I modify and refit an electric pole rack onto a wagon.
The rack had had a bit of an accident with a tree branch due to it being quite a lump higher than the cab. The customer wanted to be able to fold down the rack when not in use to avoid having the same issue again.
I designed how I was going to make the hinges and locking system in Onshape before hand. Without the wagon in the yard, I wasn’t sure how much clearance I had for the locking bolts, so I only cut 2 parts out to start with. While I was waiting I cut 4x 98mm lengths of 25mm round bar, put them in the lathe and bored them out to take a 20mm pin. By the time I had done this, the wagon had arrived and I could get on cnc plasma cutting the other hinge parts out.
To ensure the hinges were inline I only cut through one side of the box section until I had the hinges tacked on, I could then finish cutting through the box section.
Next, I cut out and pressed some plates for the locking bolts to clamp onto, these were made from 8mm plate. The locking bolts were made from 30mm round bar. These were drilled through on the milling machine so an M20 bolt could be welded into them. Before I could install these, I needed to fully weld the hinges on.
When welding the bolts into the round bar I made sure the nyloc nuts would be still on the nylon part when undo so the nuts won’t vibrate loose when the rack is down.
I also capped off all the open box sections so they wont fill with water.
The rack was then to install back onto the wagon.
To replace the strength lost I cut out and pressed some plates from 5mm to cover over where the join was and also added in a 45degree box section gusset underneath. All finished off in the trusty red oxide.

Being dyslexic, writing these video descriptions is the hardest part of the whole job. Spell check keeps me right!

Hope you enjoyed the video and thanks for watching!