OPENOVERLAND - EXPEDITION BOX V7, DRIVER SIDE
FABCO PACK, STAGE 1: THE DOOR AND THE FRAME IT HANGS IN

Draft of 2026-10-06. Nothing here has been strength-checked.
Three things to make: the welded opening frame (A1), the four door channel lengths (A2)
and the door pan (A3). Everything else is bolted on by OpenOverland.
All sizes are in mm; every STEP file is in the same coordinates, so the pieces overlay.
Material is from Ryerson.

START WITH THE DRAWINGS: expedition-box-v7-fabco-drawings.pdf, seven 11 x 17 sheets:
  1 what to make   2 opening frame, assembly and the fitting order   3 edge ring, rails and posts
  4 small frame parts   5 door channel   6 door pan, and how the door sits in the frame
  7 bill of materials, with links to the Ryerson stock and to every bought part
The STEP files are the master; a DXF is given for each plate.

STOCK
  C channel 6063-T52, 1 x 1 x 1/8 in (Ryerson 6063CH1X1/8, "CHAN 6063 T52 1 X 1 X .125", 192 or 252 in lengths)
      6333.7 mm (249.36 in) in all: the door's four lengths and the frame's top rail.
      One 252 in length is only just enough; two shorter lengths give margin.
  Square tube 6061-T6, 1 x 1 x 1/8 in (Ryerson 6061ST1X1/8, 240 in length)
      2967.1 mm (116.82 in) in all: bottom rail and two posts.
  Sheet 5052-H32, 0.080 in (Ryerson 5052SH080X48X144) for the pan.
  Sheet 5052-H32: 0.125 in for the edge ring (Ryerson 5052SH125X36X96), 0.190 in for the end webs (5052SH190X36X96).
  Plate 3/4 in for the two gussets and 1 in plate or bar for the two end pin blocks: offcuts will do.
  Square bar 6061, 3/4 in, for the insert bar (Ryerson 6061SB3/4).

A1  OPENING FRAME, WELDED     1715.1 x 626.0 over the tubes, 1765.6 long over the end pin blocks     A1-opening-frame-welded.step
  A1-01  bottom rail    1  square tube     1715.1 long, mitred 45 deg both ends
                           4 holes 6.8 through both walls and through the insert bar
  A1-02  top rail       1  C channel       1715.1 long, mitred 45 deg both ends, OPEN SIDE DOWN
                           15 holes 6.6 through both legs
  A1-03  post           2  square tube     626.0 long, mitred 45 deg both ends
  A1-04  edge ring      1  1/8 in plate    1715.1 x 626.0, opening 1633.6 x 545.2 with 101.6 corner radii   (DXF)
                           on the door side of the frame; 15 holes 6.6 countersunk 12.4 on the door side,
                           4 holes 19.4, two slots 7.5 x 27 in the top corners with their edges rounded
  A1-05  end web        2  3/16 in plate   29.9 x 626.0, one hole 10.3 for the hinge pin   (DXF; flip one)
  A1-06  gusset         2  3/4 in plate    triangle, 62.0 legs, in the two bottom corners behind the edge ring   (DXF)
  A1-07  insert bar     1  3/4 in sq bar   dressed to 18.75 square x 180.0 long, to slide inside the bottom rail.
                           PUT IT IN BEFORE THE FRAME IS WELDED: its near end is 767.6 from the front tip
                           of the bottom rail (the long point of the mitre). Drill the four 6.8 holes through rail and bar together.
  A1-08  end pin block  2  aluminium       28.5 x 25.2 x 25.4, bore 9.6 for a 3/8 in pin, tapped M6 from the top.
                           Welded to the outside of each end web, bore in line with the hole in the web.

A2  DOOR CHANNEL, NOT WELDED     A2-door-channel-set.step
  Four lengths, mitred 45 deg both ends, open side inwards. They are held by screwed corner blocks.
  A2-01  bottom      1  1697.5   web cut out between the legs for the hinge tabs: the last 125 at each end
                                   and two slots 56.8 long either side of the centre, with a 32.1 long saddle cut
                                   between them for the fixed hinge barrel; 10 holes 5.5 countersunk in the inner leg
  A2-02  top         1  1697.5   15 holes 5.5 countersunk in the inner leg
  A2-03  front end   1  611.8   6 holes 5.5 countersunk in the inner leg; half-round notch for the pin
  A2-04  rear end    1  611.8   the mirror image of A2-03

A3  DOOR PAN     0.080 in 5052-H32     A3-door-pan.step
  Finished outside size 1701.6 x 613.8, 27.4 deep. One face with the top edge and both ends folded
  back; the bottom edge stays open. Close the two top corners.
  The model has sharp folds: Fabco develops the flat with its own bend radius. The outside size governs.
  Notch for the hinge pin at the bottom of each end flange (radius 5.3), and a cut-out 32.1 wide
  in the middle of the bottom edge for the fixed hinge barrel (see the model).
  Screw holes are not in the model yet.

NOTES
  Holes and slots are in the models. If a hole is easier to drill at assembly, leave it and say so.
  Finish: everything is to be powder coated black. Agree it with OpenOverland before coating:
  bores, tongues, tabs and threads have to be masked.
  Reference: the whole assembly is on https://open-overland.com/docs/f550-crew-cab-203/bed/side-boxes
