’97 Hilux Extra Cab (RN110R) — Tray Build
First tray design-and-build project (completed Nov 2023), developed from measurements and reference photos and fabricated via hands-on welding and manual cutting. Includes learnings and what would change today: 3D scanning + CNC-cut parts for accuracy and repeatability.
Overview
This was the first full tray I designed and built, finished in November 2023. It was created from hand measurements and reference photos to get proportions and fitment right, and it became a deep learning project in welding, material choice, and structural rigidity. Looking back, the biggest improvements would be eliminating guesswork through 3D scanning during design, and using CNC-cut parts to speed fabrication while improving accuracy and repeatability compared with manual cutting and shaping.
Key Features
Designed from measurements and reference photos for fitment
Hands-on fabrication project with welding and assembly
Focused on structural rigidity and functional layout
Clear learnings captured for future iteration
Planned improvements: 3D scanning + CNC-cut components
Specifications
- Print Method
- N/A (fabricated)
- Material
- Welded steel frame with hardwood timber deck
- Fabrication
- MIG welded, manually cut and shaped
- Reference Method
- Hand measurements and reference photos
- Finish
- Gloss white paint, varnished timber floor
- Completed
- November 2023
Design Process
Measure vehicle and establish tray constraints
Draft proportions and layout using reference photos
Select materials and plan structure for rigidity
Cut and shape components manually
Weld and assemble tray structure
Review outcomes and document improvements for next build (scan + CNC)
Gallery
