Outrigger details

All the outriggers are fabricated from 3x2" box section with 1/8" wall thickness.

All the backing plates & gussets for the outriggers are made from 3/16" thick plate.

U-Bolts are custom manufactured and the details are:

• 3 of  1/2" diameter square U-bolts 6 1/8" between legs and 4" leg length
• 2  of 1/2" diameter square U-bolts 6 7/8" between legs and 3 1/2" leg length (for rear PS/DS outriggers)

Note the distance between the legs is from the inside of each leg. For the center/center distance add 1/2" (2 times the radius of each U-bolt leg.

To assemble an outrigger, I U-bolt the backing plate into position. I then position the outrigger and adjust its position until I have about 1/4" between the bottom of the rocker sill and the top of the outrigger. I then mark the position of the outrigger onto the backing plate. Then I remove the backing plate and weld off-vehicle the outrigger at the marked position.

The first drawing set is for the rear most PS and DS outriggers. The outriggers are identical.

• REARPSDS.PDF is the drawing for the outrigger itself, you need two, one for the PS and one for the DS.
• REARPLATES.PDF is the drawing of the backing plates for the rear outriggers. The PS and DS plates are the same, just flipped back to front.

The next drawing set is for the middle USDS outrigger.

• MIDUSDS.PDF is the drawing of the outrigger itself. Note the chassis is not parallel to the slider, so the outrigger has a compound angle joint to the backing plate.
• FRMIDDSPLATES.PDF is the drawing for the front and middle backing plates for the front and middle USDS outriggers.

The next drawing is for the front USDS outrigger. The plate for it is above (FRMIDDPLATES.PDF).

• FRUSDS.PDF  is the drawing of the outrigger itself. Note the chassis is not parallel to the slider, so the outrigger has a compound angle joint at the slider end - that's just how I did the it first time.

The next drawing set is for the middle USPS outrigger.

• MIDUSPS.PDF  is the drawing of the outrigger itself. Note the chassis is not parallel to the slider, so the outrigger has a compound angle joint to the backing plate.
• MIDUSPSPLATE.PDF is the drawing of the backing plate. This plate is constructed from two plates, one is 3/16" thick material and the other is 1/8" thick material. The 1/8" thick plate is 1/2" narrower (on the left side) to allow clearance for the edge and weld area of one of the toyota body mount outriggers.

The next drawing set is for the front USPS outrigger - this is the one that goes under the catalytic converter.

• FRUSPS.PDF is the drawing of the outrigger itself. This outrigger is fabricated from three separate pieces. Unlike all the other outriggers the 3x2" square tube is horizontal i.e., the 3" width is parallel to the slider and the chassis. The middle section that goes under the catalytic converter has a section cut out of it, flipped upside down and rotated 90 degrees and welded back in - this creates a cutout for clearance under the converter. To assemble this outrigger it is best done on the vehicle. Firstly bolt up the other two outriggers and position the slider alongside them. Next dry fit the three catalytic outrigger pieces and ensure they fit nicely. Use an angle grinder for fine adjustments. I then normally tack weld the first two outriggers to the slider. Finally I start to tack weld/assemble the cat converter support. Center the section under the converter with sufficient clearance side to side and under the cat. Then position the section that connects to the slider, tack weld at one or two spots. Then I support the section under the cat converter with a jack-stand and shim as necessary. I then tack weld that section to the first section. The last step is to slide in the last section that goes up against the chassis plate (which was previously bolted into position), a couple more tack welds and it is all fitted up. Go back and put some more tack welds in place and then pull the whole lot off and finish all the welding.
• FRUSPSPLATE.PDF is the drawing of the backing plate. The 4 holes in the backing plate may need to be measured on the specific vehicle to fine tune their position. The tab needs to be fitted on the vehicle, the hole drilled for the cross member bolt and then it can be tack welded to the backing plate.

If you want to download the a ZIP file that contains the .dxf version of the above pdfs then click here. With the dxf files you can import them into a CAD package and modify them or whatever takes your fancy.

To assemble the USDS slider I bolt up all three finished outriggers and then support the slider with a couple of jack-stands. Shim up as necessary and use an angle grinder for fine tuning. Then tack weld the slider to the outriggers. Pull the lot off and finish the welding.

Please refer to the photos and write-up from the previous 'page' for clarification of the drawings and further welding and fabrication hints.

All the drawings were entered using the free Learning Edition version of Turbocad. Visit http://www.imsisoft.com/ to download your own copy if you are so inclined.