[{"data":1,"prerenderedAt":1462},["ShallowReactive",2],{"navigation":3,"/docs/f550-crew-cab-203/bed/side-boxes":99,"/docs/f550-crew-cab-203/bed/side-boxes-surround":1457},[4,8,38],{"title":5,"path":6,"stem":7},"Home","/docs","docs/index",{"title":9,"path":10,"stem":11,"children":12,"page":37},"About","/docs/about","docs/1.about",[13,17,21,25,29,33],{"title":14,"path":15,"stem":16},"Manifesto","/docs/about/manifesto","docs/1.about/1.manifesto",{"title":18,"path":19,"stem":20},"Philosophy","/docs/about/philosophy","docs/1.about/2.philosophy",{"title":22,"path":23,"stem":24},"Principles","/docs/about/principles","docs/1.about/3.principles",{"title":26,"path":27,"stem":28},"Constraints","/docs/about/constraints","docs/1.about/4.constraints",{"title":30,"path":31,"stem":32},"History Timeline","/docs/about/history-timeline","docs/1.about/5.history-timeline",{"title":34,"path":35,"stem":36},"License","/docs/about/license","docs/1.about/6.license",false,{"title":39,"path":40,"stem":41,"children":42},"F550 Crew 84CA","/docs/f550-crew-cab-203","docs/2.f550-crew-cab-203/index",[43,45,55,65],{"title":44,"path":40,"stem":41},"Overview",{"title":46,"path":47,"stem":48,"children":49},"Sub-frame","/docs/f550-crew-cab-203/sub-frame","docs/2.f550-crew-cab-203/1.sub-frame/index",[50,51],{"title":44,"path":47,"stem":48},{"title":52,"path":53,"stem":54},"Installation","/docs/f550-crew-cab-203/sub-frame/installation","docs/2.f550-crew-cab-203/1.sub-frame/2.installation",{"title":56,"path":57,"stem":58,"children":59},"Bed","/docs/f550-crew-cab-203/bed","docs/2.f550-crew-cab-203/2.bed/index",[60,61],{"title":44,"path":57,"stem":58},{"title":62,"path":63,"stem":64},"Side Boxes","/docs/f550-crew-cab-203/bed/side-boxes","docs/2.f550-crew-cab-203/2.bed/1.side-boxes",{"title":66,"path":67,"stem":68,"children":69},"Upgrades","/docs/f550-crew-cab-203/upgrades","docs/2.f550-crew-cab-203/3.upgrades/index",[70,71,75,79,83,87,91,95],{"title":44,"path":67,"stem":68},{"title":72,"path":73,"stem":74},"Tie-Down Brackets","/docs/f550-crew-cab-203/upgrades/tiedown-brackets","docs/2.f550-crew-cab-203/3.upgrades/1.tiedown-brackets",{"title":76,"path":77,"stem":78},"150A DC-DC","/docs/f550-crew-cab-203/upgrades/150a-dc-dc-charging","docs/2.f550-crew-cab-203/3.upgrades/2.150a-dc-dc-charging",{"title":80,"path":81,"stem":82},"DC-DC Cooling","/docs/f550-crew-cab-203/upgrades/dc-dc-cooling","docs/2.f550-crew-cab-203/3.upgrades/3.dc-dc-cooling",{"title":84,"path":85,"stem":86},"Lifting Points","/docs/f550-crew-cab-203/upgrades/lifting-points","docs/2.f550-crew-cab-203/3.upgrades/4.lifting-points",{"title":88,"path":89,"stem":90},"Rear Recovery","/docs/f550-crew-cab-203/upgrades/rear-recovery-point","docs/2.f550-crew-cab-203/3.upgrades/5.rear-recovery-point",{"title":92,"path":93,"stem":94},"Spare Tire","/docs/f550-crew-cab-203/upgrades/spare-tire-carrier","docs/2.f550-crew-cab-203/3.upgrades/6.spare-tire-carrier",{"title":96,"path":97,"stem":98},"Onboard Air","/docs/f550-crew-cab-203/upgrades/onboard-air","docs/2.f550-crew-cab-203/3.upgrades/7.onboard-air",{"id":100,"title":62,"body":101,"description":1448,"extension":1449,"links":1450,"meta":1451,"navigation":1452,"path":63,"seo":1453,"stem":64,"__hash__":1456},"docs/docs/2.f550-crew-cab-203/2.bed/1.side-boxes.md",{"type":102,"value":103,"toc":1433},"minimark",[104,118,187,196,201,204,211,293,296,301,312,361,364,495,499,502,614,618,753,758,978,981,985,1043,1047,1074,1078,1116,1119,1123,1126,1132,1368,1370,1374],[105,106,107,108,112,113,117],"p",{},"Two boxes, one each side of the bed, beside the camper's lower body and under its wings. They are the first module of the ",[109,110,111],"a",{"href":57},"bed",". ",[114,115,116],"strong",{},"Stage one is the door",": the driver-side door and the frame it hangs in, built and proven on a bench before the box goes round it.",[119,120,121,152],"tabs",{},[122,123,125],"tabs-item",{"label":124},"3D Preview",[126,127,137],"model-explorer",{":groups":128,":positions":129,":shadowIntensity":130,"alt":131,"animationName":132,"cameraOrbit":133,"cameraTarget":134,"height":135,"src":136},"[{\"label\":\"Opening frame\",\"material\":1},{\"label\":\"Door channel\",\"material\":2},{\"label\":\"Door pan\",\"material\":3},{\"label\":\"Blocks and plates\",\"material\":4},{\"label\":\"Panel and round edge\",\"material\":5},{\"label\":\"Latches\",\"material\":6},{\"label\":\"Seal\",\"material\":7},{\"label\":\"Pins and fasteners\",\"material\":8},{\"label\":\"Stay cords\",\"material\":9},{\"label\":\"Shell\",\"material\":0,\"hidden\":true}]","[{\"label\":\"Door shut\",\"time\":0},{\"label\":\"Bench at 90°\",\"time\":1,\"default\":true},{\"label\":\"Hanging at 180°\",\"time\":2}]","0","Expedition Box V7 — the pivot door open as a bench, in its opening frame","Door","50deg 62deg 3.4m","0.8m 0.25m -1.27m","420px","/assets/sidebox-v7.glb",[105,138,139,140,143,144,147,148,151],{},"The ",[114,141,142],{},"V7"," door in its opening frame — drag to rotate, scroll or pinch to zoom. The first row swings the door: shut, a bench at 90° on its stay cords, or hanging at 180°. The second row hides parts: take off the ",[114,145,146],{},"door pan"," and the ",[114,149,150],{},"panel"," to see the channel frame and the blocks inside.",[122,153,155,162,171,179],{"label":154},"Files",[105,156,157,158,161],{},"Free to download and use under the ",[109,159,160],{"href":35},"project licence",".",[163,164],"download-card",{"description":165,"format":166,"href":167,"icon":168,"size":169,"title":170},"Only the pieces the fabricator makes — the welded opening frame, the four door channel lengths and the door pan. The drawings, one STEP file per piece, a DXF for each plate, and the cut list.","ZIP","/files/f550-crew-cab-203/side-boxes/expedition-box-v7-fabco-pack.zip","i-lucide-package","356 KB","Fabco pack — stage 1",[163,172],{"description":173,"format":174,"href":175,"icon":176,"size":177,"title":178},"Seven 11 × 17 in sheets, in mm and inches — what to make, the frame with its fitting order, the edge ring and rails with a hole table, the small parts, the door channel, the pan with the fit of the door in the frame, and the bill of materials with links to every supplier part.","PDF","/files/f550-crew-cab-203/side-boxes/expedition-box-v7-fabco-drawings.pdf","i-lucide-ruler","162 KB","Fabco drawings",[163,180],{"description":181,"format":182,"href":183,"icon":184,"size":185,"title":186},"The whole box with the door shut, one named body per kind of piece, in the same groups as this page. Fasteners and latches are reference shapes; the stay cords are left out.","STEP","/files/f550-crew-cab-203/side-boxes/expedition-box-v7.step","i-lucide-box","2.7 MB","3D model — V7",[188,189,190],"warning",{},[105,191,192,195],{},[114,193,194],{},"Draft — V7, 06 Oct 2026."," A CAD model. Nothing has been strength-checked and nothing is released for fabrication.",[197,198,200],"h2",{"id":199},"stage-one-the-door","Stage one — the door",[105,202,203],{},"A flush door that pivots on its rounded bottom edge: shut, a bench at 90° on two stay cords, hanging flat at 180°. Nothing shows on its face — no hinge, no fastener, no handle. Three electronic latches hold it and push it open.",[105,205,206,207,210],{},"It is a kit. ",[114,208,209],{},"The fabricator cuts, folds and welds three things. Everything else bolts on",", with one kind of screw wherever possible. Nothing on the door is welded, so it comes apart again.",[212,213,214,225],"table",{},[215,216,217],"thead",{},[218,219,220,223],"tr",{},[221,222],"th",{},[221,224],{},[226,227,228,237,245,253,261,269,277,285],"tbody",{},[218,229,230,234],{},[231,232,233],"td",{},"Door, outside",[231,235,236],{},"1701.6 × 613.8 × 27.4 mm, about 25 kg",[218,238,239,242],{},[231,240,241],{},"Opening frame, outside",[231,243,244],{},"1715.1 × 626.0 mm",[218,246,247,250],{},[231,248,249],{},"Clear opening",[231,251,252],{},"1633.6 × 545.2 mm, 4 in corner radii",[218,254,255,258],{},[231,256,257],{},"Gaps, door to box",[231,259,260],{},"2 mm at the top and both ends",[218,262,263,266],{},[231,264,265],{},"Hinge",[231,267,268],{},"A 1 in round edge on three 3/8 in pins — one each end, one fixed pivot in the middle",[218,270,271,274],{},[231,272,273],{},"Latches",[231,275,276],{},"Three, 12–24 V, with kick-out",[218,278,279,282],{},[231,280,281],{},"Finish",[231,283,284],{},"Powder coat, black; screws stay plain stainless",[218,286,287,290],{},[231,288,289],{},"Box, later stage",[231,291,292],{},"605 × 631 × 2499 mm",[105,294,295],{},"All hardware is stainless steel. Sizes are in millimetres unless marked; quantities are for one door and its frame.",[297,298,300],"h3",{"id":299},"a-fabco-makes","A — Fabco makes",[105,302,303,304,307,308,311],{},"These three are the ",[109,305,306],{"href":167},"Fabco pack",": a STEP file per piece, a DXF per plate, and ",[109,309,310],{"href":175},"seven sheets of drawings"," with the fitting order and the bill of materials.",[212,313,314,324],{},[215,315,316],{},[218,317,318,321],{},[221,319,320],{},"Piece",[221,322,323],{},"What it is",[226,325,326,340,351],{},[218,327,328,334],{},[231,329,330,333],{},[114,331,332],{},"A1 Opening frame",", welded",[231,335,336,337],{},"Bottom rail 1715.1 and two posts 626.0 in square tube; top rail 1715.1 in channel, open side down; all mitred. A 1/8 in edge ring on the face, two 3/16 in end webs, two 3/4 in corner gussets, and two end pin blocks. A solid bar 18.75 square × 180 goes inside the bottom rail ",[114,338,339],{},"before welding",[218,341,342,348],{},[231,343,344,347],{},[114,345,346],{},"A2 Door channel",", not welded",[231,349,350],{},"Two lengths of 1697.5 and two of 611.8 in channel, mitred at 45°",[218,352,353,358],{},[231,354,355],{},[114,356,357],{},"A3 Door pan",[231,359,360],{},"One sheet folded over the face, the top and both ends: 1701.6 × 613.8, 27.4 deep",[105,362,363],{},"Stock is from Ryerson, where Fabco buys.",[212,365,366,379],{},[215,367,368],{},[218,369,370,373,376],{},[221,371,372],{},"Stock",[221,374,375],{},"Ryerson part",[221,377,378],{},"Used for",[226,380,381,405,421,437,453,468,484],{},[218,382,383,386,402],{},[231,384,385],{},"C channel 6063-T52, 1 × 1 × 1/8 in",[231,387,388,395,396,401],{},[109,389,394],{"href":390,"rel":391,"target":393},"https://www.ryerson.com/store/products/458442f7-fa42-431c-87fb-657d4404fb78/?altPartNumber=160001620",[392],"nofollow","_blank","6063CH1X1/8",", 252 in (also ",[109,397,400],{"href":398,"rel":399,"target":393},"https://www.ryerson.com/store/products/1d4be600-6b0d-4dfd-ba56-1a89da118aee/?altPartNumber=160001619",[392],"192 in",")",[231,403,404],{},"Door channel and top rail: 6334 mm (249 in) in all, so one 252 in length is only just enough",[218,406,407,410,418],{},[231,408,409],{},"Square tube 6061-T6, 1 × 1 × 1/8 in",[231,411,412,417],{},[109,413,416],{"href":414,"rel":415,"target":393},"https://www.ryerson.com/store/products/50ea3dbd-3d24-48af-9838-7826342a0df6/?altPartNumber=100013173",[392],"6061ST1X1/8",", 240 in",[231,419,420],{},"Bottom rail and posts: 2967 mm (117 in)",[218,422,423,426,434],{},[231,424,425],{},"Sheet 5052-H32, 0.080 in",[231,427,428,433],{},[109,429,432],{"href":430,"rel":431,"target":393},"https://www.ryerson.com/store/products/16ad156a-d87b-42ef-aa67-a0ff2ecfe13d/?altPartNumber=160002051",[392],"5052SH080X48X144",", 48 × 144 in",[231,435,436],{},"Door pan; one sheet makes two",[218,438,439,442,450],{},[231,440,441],{},"Sheet 5052-H32, 0.125 in",[231,443,444,449],{},[109,445,448],{"href":446,"rel":447,"target":393},"https://www.ryerson.com/store/products/4a21da29-e695-41a7-92a7-1930b9783dc8/?altPartNumber=160002029",[392],"5052SH125X36X96",", 36 × 96 in",[231,451,452],{},"Edge ring",[218,454,455,458,465],{},[231,456,457],{},"Sheet 5052-H32, 0.190 in",[231,459,460,449],{},[109,461,464],{"href":462,"rel":463,"target":393},"https://www.ryerson.com/store/products/51a0a57c-4bd3-46b7-94dd-9f57c16992b8/?altPartNumber=160002018",[392],"5052SH190X36X96",[231,466,467],{},"End webs",[218,469,470,473,481],{},[231,471,472],{},"Square bar 6061, 3/4 in",[231,474,475,480],{},[109,476,479],{"href":477,"rel":478,"target":393},"https://www.ryerson.com/store/products/0b073282-4721-4903-8b9c-2b9a12cdc5a3/?altPartNumber=160001141",[392],"6061SB3/4",", 144 in",[231,482,483],{},"Insert bar, 180 mm",[218,485,486,489,492],{},[231,487,488],{},"Plate, 3/4 in and 1 in",[231,490,491],{},"Offcuts",[231,493,494],{},"Two gussets and two end pin blocks",[297,496,498],{"id":497},"b-made-parts","B — Made parts",[105,500,501],{},"Machined from the 3D model. All aluminium except the strikers.",[212,503,504,517],{},[215,505,506],{},[218,507,508,511,514],{},[221,509,510],{},"Part",[221,512,513],{},"Qty",[221,515,516],{},"Job",[226,518,519,530,540,551,562,573,584,594,604],{},[218,520,521,524,527],{},[231,522,523],{},"B1 Top corner blocks",[231,525,526],{},"2, a mirrored pair",[231,528,529],{},"Hold the mitred door frame together at the top; carry the stay-cord pin",[218,531,532,535,537],{},[231,533,534],{},"B2 Bottom corner blocks",[231,536,526],{},[231,538,539],{},"The same at the bottom, with the hinge barrel in one piece. Hard-anodised",[218,541,542,545,548],{},[231,543,544],{},"B3 Middle hinge blocks",[231,546,547],{},"2, identical",[231,549,550],{},"A 60 mm hinge barrel with a tab up through the channel. Hard-anodised",[218,552,553,556,559],{},[231,554,555],{},"B4 Hinge plates",[231,557,558],{},"2",[231,560,561],{},"1/8 in plate, 191.6 × 114.6, on both faces of the panel round the middle hinge",[218,563,564,567,570],{},[231,565,566],{},"B5 Fixed pivot",[231,568,569],{},"1",[231,571,572],{},"A 30 mm barrel on a 152 × 25 base plate, bolted to the bottom rail",[218,574,575,578,581],{},[231,576,577],{},"B6 Striker blocks",[231,579,580],{},"3",[231,582,583],{},"A tongue in the door's top channel; carry the striker",[218,585,586,589,591],{},[231,587,588],{},"B7 Strikers",[231,590,580],{},[231,592,593],{},"316 stainless. Bolted on, so one can be changed from inside the box",[218,595,596,599,601],{},[231,597,598],{},"B8 Latch receivers",[231,600,580],{},[231,602,603],{},"Clip into the top rail from below and carry the latch",[218,605,606,609,611],{},[231,607,608],{},"B9 Stay corner blocks",[231,610,526],{},[231,612,613],{},"In the top corners of the opening frame; the slot for the stay-cord pin",[297,615,617],{"id":616},"c-bought-parts","C — Bought parts",[212,619,620,631],{},[215,621,622],{},[218,623,624,626,629],{},[221,625,510],{},[221,627,628],{},"Supplier and part number",[221,630,513],{},[226,632,633,648,664,680,695,715,731,742],{},[218,634,635,638,646],{},[231,636,637],{},"Latch, stainless, with kick-out",[231,639,640,641],{},"Southco ",[109,642,645],{"href":643,"rel":644,"target":393},"https://southco.com/en_us_int/r4-em-732-173-b",[392],"R4-EM-732-173-B",[231,647,580],{},[218,649,650,653,661],{},[231,651,652],{},"Door seal, push-on",[231,654,655,656],{},"McMaster ",[109,657,660],{"href":658,"rel":659,"target":393},"https://www.mcmaster.com/12335A55/",[392],"12335A55",[231,662,663],{},"25 ft",[218,665,666,669,677],{},[231,667,668],{},"Half round, 6061, 1 in",[231,670,655,671,676],{},[109,672,675],{"href":673,"rel":674,"target":393},"https://www.mcmaster.com/8242T71/",[392],"8242T71",", 6 ft length",[231,678,679],{},"2 pieces of 647.8",[218,681,682,685,693],{},[231,683,684],{},"Hinge pin, 316, 3/8 in",[231,686,655,687,692],{},[109,688,691],{"href":689,"rel":690,"target":393},"https://www.mcmaster.com/97395A935/",[392],"97395A935"," — 3/8 × 6 in dowel pin, cut to 5-1/2 in",[231,694,580],{},[218,696,697,700,713],{},[231,698,699],{},"Thrust washer for a 3/8 in pin",[231,701,655,702,707,708],{},[109,703,706],{"href":704,"rel":705,"target":393},"https://www.mcmaster.com/2795T12/",[392],"2795T12"," — acetal, 3/4 in OD × 1/16 in. Candidate; the 316 alternative is ",[109,709,712],{"href":710,"rel":711,"target":393},"https://www.mcmaster.com/91525A136/",[392],"91525A136",[231,714,558],{},[218,716,717,720,728],{},[231,718,719],{},"Flush grease fitting, stainless",[231,721,655,722,727],{},[109,723,726],{"href":724,"rel":725,"target":393},"https://www.mcmaster.com/10595K37/",[392],"10595K37"," — M6 × 1 thread. Candidate",[231,729,730],{},"5",[218,732,733,736,739],{},[231,734,735],{},"Door panel, 1 in cored board",[231,737,738],{},"Not chosen — Coosa Bluewater 26 is the candidate",[231,740,741],{},"1, about 1691 × 605",[218,743,744,747,750],{},[231,745,746],{},"Stay cord, about 6 mm nylon",[231,748,749],{},"Not chosen",[231,751,752],{},"2, about 1 m each",[105,754,755],{},[114,756,757],{},"Fasteners",[212,759,760,774],{},[215,761,762],{},[218,763,764,767,769,771],{},[221,765,766],{},"Fastener",[221,768,628],{},[221,770,513],{},[221,772,773],{},"Where",[226,775,776,795,814,832,849,868,885,903,919,935,953],{},[218,777,778,781,789,792],{},[231,779,780],{},"M5 × 12 Torx flat head, 18-8",[231,782,655,783,788],{},[109,784,787],{"href":785,"rel":786,"target":393},"https://www.mcmaster.com/92703A162/",[392],"92703A162",", pack of 50",[231,790,791],{},"41",[231,793,794],{},"Door, from the inner face: corner blocks 24, striker blocks 9, middle hinge blocks 8",[218,796,797,800,808,811],{},[231,798,799],{},"M6 × 45 Torx flat head, 18-8",[231,801,655,802,807],{},[109,803,806],{"href":804,"rel":805,"target":393},"https://www.mcmaster.com/92703A471/",[392],"92703A471",", pack of 10",[231,809,810],{},"15",[231,812,813],{},"Top rail, bolted right through: latch receivers 9, stay blocks 6",[218,815,816,819,826,829],{},[231,817,818],{},"M6 × 30 Torx flat head, 18-8",[231,820,655,821,807],{},[109,822,825],{"href":823,"rel":824,"target":393},"https://www.mcmaster.com/92703A467/",[392],"92703A467",[231,827,828],{},"6",[231,830,831],{},"Strikers",[218,833,834,837,844,846],{},[231,835,836],{},"M6 × 35 Torx pan head, 18-8",[231,838,655,839,807],{},[109,840,843],{"href":841,"rel":842,"target":393},"https://www.mcmaster.com/90362A186/",[392],"90362A186",[231,845,828],{},[231,847,848],{},"Latches to their receivers",[218,850,851,854,862,865],{},[231,852,853],{},"M6 nylon-insert lock nut, 18-8",[231,855,655,856,861],{},[109,857,860],{"href":858,"rel":859,"target":393},"https://www.mcmaster.com/93625A250/",[392],"93625A250",", pack of 100",[231,863,864],{},"27",[231,866,867],{},"Top rail 15, strikers 6, latches 6",[218,869,870,873,880,882],{},[231,871,872],{},"M6 washer, 18-8",[231,874,655,875,861],{},[109,876,879],{"href":877,"rel":878,"target":393},"https://www.mcmaster.com/93475A250/",[392],"93475A250",[231,881,864],{},[231,883,884],{},"Top rail 15, latches 12",[218,886,887,890,897,900],{},[231,888,889],{},"1/4\"-20 × 1-1/2 in carriage bolt, 316",[231,891,655,892],{},[109,893,896],{"href":894,"rel":895,"target":393},"https://www.mcmaster.com/93180A230/",[392],"93180A230",[231,898,899],{},"4",[231,901,902],{},"Fixed pivot",[218,904,905,908,915,917],{},[231,906,907],{},"1/4\"-20 serrated flange nut, 316",[231,909,655,910,807],{},[109,911,914],{"href":912,"rel":913,"target":393},"https://www.mcmaster.com/91343A100/",[392],"91343A100",[231,916,899],{},[231,918,902],{},[218,920,921,924,931,933],{},[231,922,923],{},"1/4 in washer, 316",[231,925,655,926,861],{},[109,927,930],{"href":928,"rel":929,"target":393},"https://www.mcmaster.com/90107A029/",[392],"90107A029",[231,932,899],{},[231,934,902],{},[218,936,937,940,948,950],{},[231,938,939],{},"M6 × 10 cup-point set screw, 316",[231,941,655,942,947],{},[109,943,946],{"href":944,"rel":945,"target":393},"https://www.mcmaster.com/92029A254/",[392],"92029A254",", pack of 25",[231,949,558],{},[231,951,952],{},"End pins",[218,954,955,958,972,975],{},[231,956,957],{},"M3 × 8 flat head, 18-8",[231,959,655,960,965,966,971],{},[109,961,964],{"href":962,"rel":963,"target":393},"https://www.mcmaster.com/92703A149/",[392],"92703A149"," (Torx Plus) or ",[109,967,970],{"href":968,"rel":969,"target":393},"https://www.mcmaster.com/92125A128/",[392],"92125A128"," (hex) — not made in plain Torx",[231,973,974],{},"About 110",[231,976,977],{},"Door pan, about every 2 in. Not drawn yet",[105,979,980],{},"Anti-seize on every stainless thread, isolating paste wherever stainless touches aluminium, and polyurethane sealant under the 15 top-rail bolt heads.",[297,982,984],{"id":983},"assembly","Assembly",[986,987,988,995,1001,1007,1013,1019,1025,1031,1037],"ol",{},[989,990,991,994],"li",{},[114,992,993],{},"Opening frame."," It arrives welded: rails, edge ring, end webs, gussets and end pin blocks, with the bar already inside the bottom rail.",[989,996,997,1000],{},[114,998,999],{},"Door frame."," Lay out the bottom channel and the two end channels. Slide in the two bottom corner blocks and screw them — three M5 each side of each corner. Fix the two half rounds under the bottom channel.",[989,1002,1003,1006],{},[114,1004,1005],{},"Hinge."," Push the centre pin through the fixed pivot and slide a middle hinge block onto each end. Their tabs go up through the bottom channel.",[989,1008,1009,1012],{},[114,1010,1011],{},"Panel."," Slide the panel in from the top with the hinge plates and the three striker blocks. Close the frame with the top channel and the two top corner blocks.",[989,1014,1015,1018],{},[114,1016,1017],{},"Pan."," Fit the pan over the face, the top and both ends, and screw it on.",[989,1020,1021,1024],{},[114,1022,1023],{},"Hang the door."," Four carriage bolts go from the fixed pivot through the bottom rail and its bar; the nuts go on inside. Push the two end pins in from inside, each with its thrust washer, and lock the set screws.",[989,1026,1027,1030],{},[114,1028,1029],{},"Latches."," Clip the three receivers into the top rail and bolt each through with three M6 × 45. Bolt the latches under them and the strikers onto the door.",[989,1032,1033,1036],{},[114,1034,1035],{},"Seal and stays."," Push the seal onto the edge ring. Bolt the two stay corner blocks into the top rail and fit the cords.",[989,1038,1039,1042],{},[114,1040,1041],{},"Check."," Swing the door from shut to 180°, check the 2 mm gaps, and check that all three latches catch and kick out.",[297,1044,1046],{"id":1045},"why-a-pivot-door","Why a pivot door",[1048,1049,1050,1056,1062,1068],"ul",{},[989,1051,1052,1055],{},[114,1053,1054],{},"Nothing on the face."," One flat panel from top to bottom, with a single round edge that is also the bottom corner of the box.",[989,1057,1058,1061],{},[114,1059,1060],{},"No hinge to attack."," No exposed pin, no knuckle, and nothing to lever against. Every fastener undoes from inside.",[989,1063,1064,1067],{},[114,1065,1066],{},"A bench and a clear side."," At 90° it is a work surface; at 180° it hangs in the plane it was shut in.",[989,1069,1070,1073],{},[114,1071,1072],{},"It is still an aluminium box."," The 2 mm gaps admit a thin blade, which meets the 25 mm edge of the door, not a latch.",[297,1075,1077],{"id":1076},"open-points","Open points",[1048,1079,1080,1086,1092,1098,1104,1110],{},[989,1081,1082,1085],{},[114,1083,1084],{},"Strength."," Nothing is calculated: the pins, the fixed pivot and its bolts, the stay cords, the bench. There is no bench rating.",[989,1087,1088,1091],{},[114,1089,1090],{},"Not drawn yet."," The pan screws, the latch screws and the eight middle hinge block screws.",[989,1093,1094,1097],{},[114,1095,1096],{},"To choose."," The panel product, the stay cord and its pin, who machines the made parts, and whether the outer hinge plate is bonded or bolted.",[989,1099,1100,1103],{},[114,1101,1102],{},"Powder coat."," Bores, tongues, tabs, threads and striker bars have to be masked.",[989,1105,1106,1109],{},[114,1107,1108],{},"Seal gap."," The 7 mm between the edge ring and the door is an estimate — check it with the seal in hand.",[989,1111,1112,1115],{},[114,1113,1114],{},"When the shell goes on."," Weld the two end pin blocks to the shell's front sheet as well.",[1117,1118],"hr",{},[197,1120,1122],{"id":1121},"later-stages-the-box","Later stages — the box",[105,1124,1125],{},"The door is stage one. The box round it — one brake-formed 5052 shell, 605 × 631 × 2499 mm — and what goes inside come after. These are the requirements it will be checked against.",[105,1127,1128,1131],{},[114,1129,1130],{},"Status key:"," 🟡 On paper — confirm on the truck · ⚪ Open · ❌ Not designed",[212,1133,1134,1147],{},[215,1135,1136],{},[218,1137,1138,1141,1144],{},[221,1139,1140],{},"ID",[221,1142,1143],{},"Requirement",[221,1145,1146],{},"Status",[226,1148,1149,1160,1171,1182,1193,1204,1215,1226,1237,1253,1263,1274,1285,1296,1307,1317,1327,1338,1348,1358],{},[218,1150,1151,1154,1157],{},[231,1152,1153],{},"SB-01",[231,1155,1156],{},"Minimise welding",[231,1158,1159],{},"🟡 The door is bolted throughout; the opening frame and the shell are welded",[218,1161,1162,1165,1168],{},[231,1163,1164],{},"SB-02",[231,1166,1167],{},"Brake-formed 5052-H32",[231,1169,1170],{},"🟡 Specified for the shell and the door pan",[218,1172,1173,1176,1179],{},[231,1174,1175],{},"SB-03",[231,1177,1178],{},"Formable by the shop that builds it",[231,1180,1181],{},"⚪ Fabco to confirm the bends and that the blank, about 1798 × 2499 mm, fits a 72 in sheet",[218,1183,1184,1187,1190],{},[231,1185,1186],{},"SB-04",[231,1188,1189],{},"Fill the available space",[231,1191,1192],{},"⚪ Envelope taken from the 05 Oct 2026 drawing; not checked on the truck",[218,1194,1195,1198,1201],{},[231,1196,1197],{},"SB-05",[231,1199,1200],{},"Carried by the sub-frame outriggers",[231,1202,1203],{},"⚪ Mount holes not in the model",[218,1205,1206,1209,1212],{},[231,1207,1208],{},"SB-06",[231,1210,1211],{},"Follow the camper's edge",[231,1213,1214],{},"🟡 605 mm wide, rear end cut at 14.7°; measure the camper",[218,1216,1217,1220,1223],{},[231,1218,1219],{},"SB-07",[231,1221,1222],{},"Camper tie-downs end inside the boxes",[231,1224,1225],{},"❌",[218,1227,1228,1231,1234],{},[231,1229,1230],{},"SB-08",[231,1232,1233],{},"A 6 ft 5 in × 20 in surfboard, right box",[231,1235,1236],{},"❌ Fits inside but does not load straight in — the opening is 1633.6 mm against a 1956 mm board",[218,1238,1239,1242,1245],{},[231,1240,1241],{},"SB-09",[231,1243,1244],{},"Removable 20 gal propane tank, left box, in its own vented compartment",[231,1246,1247,1248],{},"❌ Tank chosen: ",[109,1249,1252],{"href":1250,"rel":1251,"target":393},"https://flamekingproducts.com/products/flame-king-20-3-gal-asme-rv-trailer-propane-tank-cylinder-with-mount-brackets",[392],"Flame King YSN203",[218,1254,1255,1258,1261],{},[231,1256,1257],{},"SB-10",[231,1259,1260],{},"Fuel-fill compartment with its own door",[231,1262,1225],{},[218,1264,1265,1268,1271],{},[231,1266,1267],{},"SB-11",[231,1269,1270],{},"A planned way through for every camper fixture",[231,1272,1273],{},"❌ Survey the camper",[218,1275,1276,1279,1282],{},[231,1277,1278],{},"SB-12",[231,1280,1281],{},"Storage space first; loading the camper can be hard",[231,1283,1284],{},"⚪ Test at the first fit",[218,1286,1287,1290,1293],{},[231,1288,1289],{},"SB-13",[231,1291,1292],{},"Load and unload the camper with the boxes on",[231,1294,1295],{},"⚪",[218,1297,1298,1301,1304],{},[231,1299,1300],{},"SB-14",[231,1302,1303],{},"Narrower than the width between the camper jacks",[231,1305,1306],{},"⚪ Not measured",[218,1308,1309,1312,1315],{},[231,1310,1311],{},"SB-15",[231,1313,1314],{},"Clear under the raised camper",[231,1316,1306],{},[218,1318,1319,1322,1325],{},[231,1320,1321],{},"SB-16",[231,1323,1324],{},"Everything disconnects from inside the boxes",[231,1326,1295],{},[218,1328,1329,1332,1335],{},[231,1330,1331],{},"SB-17",[231,1333,1334],{},"Doors work with the camper on and off",[231,1336,1337],{},"🟡 Needs about 1710 mm between the front and rear jacks, and 601 mm clear below the box for the door to hang at 180°",[218,1339,1340,1343,1346],{},[231,1341,1342],{},"SB-18",[231,1344,1345],{},"Seasonal modules on common hard points",[231,1347,1295],{},[218,1349,1350,1353,1356],{},[231,1351,1352],{},"SB-19",[231,1354,1355],{},"Floor L-track",[231,1357,1295],{},[218,1359,1360,1363,1366],{},[231,1361,1362],{},"SB-20",[231,1364,1365],{},"Slide-out platform",[231,1367,1295],{},[1117,1369],{},[197,1371,1373],{"id":1372},"changelog","Changelog",[212,1375,1376,1389],{},[215,1377,1378],{},[218,1379,1380,1383,1386],{},[221,1381,1382],{},"Version",[221,1384,1385],{},"Date",[221,1387,1388],{},"Description",[226,1390,1391,1402,1413,1423],{},[218,1392,1393,1396,1399],{},[231,1394,1395],{},"v0.1",[231,1397,1398],{},"2026-09",[231,1400,1401],{},"Functional requirements",[218,1403,1404,1407,1410],{},[231,1405,1406],{},"v0.2 – v0.5",[231,1408,1409],{},"2026-10",[231,1411,1412],{},"Drafts V4 and V5: a flush door, then the pivot door with hidden pins and stays",[218,1414,1415,1418,1420],{},[231,1416,1417],{},"v0.6",[231,1419,1409],{},[231,1421,1422],{},"Draft V7 on the final envelope: tube opening frame, push-on seal, a hinge that can be greased and taken apart",[218,1424,1425,1428,1430],{},[231,1426,1427],{},"v0.7",[231,1429,1409],{},[231,1431,1432],{},"Page cut down to stage one, the door: a bolted kit in three groups — what Fabco makes, made parts and bought parts, with suppliers and part numbers. 3D model and STEP replaced with V7 (the door now swings in the preview), Fabco pack and drawings added, FreeCAD download withdrawn",{"title":1434,"searchDepth":1435,"depth":1435,"links":1436},"",2,[1437,1446,1447],{"id":199,"depth":1435,"text":200,"children":1438},[1439,1441,1442,1443,1444,1445],{"id":299,"depth":1440,"text":300},3,{"id":497,"depth":1440,"text":498},{"id":616,"depth":1440,"text":617},{"id":983,"depth":1440,"text":984},{"id":1045,"depth":1440,"text":1046},{"id":1076,"depth":1440,"text":1077},{"id":1121,"depth":1435,"text":1122},{"id":1372,"depth":1435,"text":1373},"The two side boxes of the bed. Stage one is the driver-side door — a flush pivot door that goes together like a kit.","md",null,{},{"title":62},{"title":1454,"description":1455},"F-550 Side Boxes — Expedition Box V7 | OpenOverland","The OpenOverland F-550 side boxes. Stage one is the door — a flush aluminium pivot door built as a kit, with the fabricator's pack, every part, supplier and part number, and the 3D model.","VnQq6qtOLP4vc5teZ_Z12MNF6i0xn_tKiL49zGG-tMY",[1458,1460],{"title":44,"path":57,"stem":58,"description":1459,"children":-1},"The bed — the modular storage garage that bolts to the sub-frame. Shared philosophy and requirements for every module.",{"title":44,"path":67,"stem":68,"description":1461,"children":-1},"Upgrades to the F-550 and its nuCamp Cirrus 920 camper — the reasoning, analysis and files to do the same.",1791325510574]