Homemade Flatbed
Flatbeds with removable side-rails were standard on the first trucks every produced which made them ideal for hauling everything from farm equipment to refrigerated meat. Fortunately, that versatility still runs deep in a truck's bones, and can be easy to restore with a homemade flatbed.
The Plan
If you've ever built a wall, porch deck or roof, than you already know the basics of flatbed construction. The only real difference is that you'll be substituting 2 x 3 inch steel tubing and welds for 2 x 4 lumber and nails. Aside from the deck, you're going to need to build a "headache rack" (think of it like the head-board on a bed) to protect the cab of your truck. There are a few other things you can do to make your truck more versatile.
Laying the Bed Out
After you have the old bed off, measure the width of your truck's cab just above the framerails, and subtract four inches. This will be the length of your crossmembers, and how many you'll need depends on the length of bed you desire. Start by marking your frame rail just above the axle centerline, and mark six inches on either side. This will be the centerline for your first crossmembers. Mark your frame every twelve inches on either side of the two center cross members, and use this to center the rest of them. Tack the 2 x 3 inch rectangular steel crossmembers into place. Use some downward facing three foot c-channel to fill the gaps in between your crossmembers, centered halfway between the framerails and the end of the crossmembers. Cover the whole thing with a one-eighth of an inch steel plate.
Headache Rack
Frame the area behind you cab with the same 2 x 3 inch tubing you used with the crossmembers. It is a good idea to make this "headboard" a little bit bigger than the cab of the truck to allow you to rest long objects on top without hitting the truck. You can fill the empty areas in your headache rack with one-sixteenth of an inch steel plate, diamond plate or steel grating.
Bumper and Options
Most trucks can retain the stock bumper, but many people choose to replace it with one fabricated from four foot channel iron covered with steel plate. Take a look at the back of any tractor trailer, and you'll have the basic idea.
You can also install a fifth wheel trailer receiver between the two center crossmembers, and feel free to recess it into the deck. Many people also opt to make removable side rails for their beds, or to install a winch onto the headache rack to facilitate the loading and unloading of heavy objects like cars and hay-bales.
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