Bolt-On Tray Tailboard — KT Kustoms
Retrofit rear tailboard for a ute tray, drawn for laser cutting and folding in sheet aluminium, carrying six 122.5 mm round lights and bolting over the existing tray.
Overview
A retrofit rear tailboard designed to fit over an existing ute tray without modifying it, so the lighting upgrade could be bolted on rather than fabricated in place. The assembly is broken into three sheet aluminium pieces, each detailed as a flat pattern with fold lines and bend radii ready for laser cutting and folding. Six 122.5 mm round light cutouts sit in two clusters either side of a recessed centre panel carrying the KT Kustoms badge. Folded return brackets with 6.88 mm hole patterns handle the bolt-on mounting to the tray.
Key Features
Bolt-on retrofit to an existing tray, no full rebuild required
Six Ø122.5 mm cutouts sized for Roadvision BR122ARR round lights
Rear profile shaped to clear APB undertray boxes
Corner angles matched to the existing tray geometry
Three-piece folded construction with separate bolt-on mounting strips
Specifications
- Material
- Sheet aluminium
- Fabrication
- Laser cut and folded
- Components Modelled
- 3 pieces (PC1, PC2, PC3 x2)
- Dimensions
- PC2 flat length 1929.57 mm, height 314.57 mm
- Lighting
- 6 x 122.5 mm round lights
- Fastening
- Bolt-on brackets, 6.88 mm holes, 60 degree folded returns
Design Process
Gather dimensions from the existing tray, corners and undertray boxes
Model the tailboard in CAD around the confirmed tray geometry
Set light cutout diameter and spacing to suit the Roadvision units
Split the design into three sheet pieces with defined bend lines
Produce flat patterns, DXF files and dimensioned drawing sheets
Supply files to KT Kustoms for external laser cutting and folding
Gallery
