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If you're only looking to do 2-3" total, you can do that with aluminum rectangle tubing. To fit the channel in the walls, you need 1.5" wide. In that size, they make 2", 3" and 4" tall tubing. You could just cut the huck bolts off, lift the roof, add in the rectangle tubing and rivet...
It is much easier to cut all of the huck bolts along the edges (air chisel took me 5 minutes from the inside) and build a frame to raise it. Then I made corner pieces to weld onto the box, then I skinned the outside. That's what I did.
Yeah, that support bar for the bed racks, was the only part that is steel in the box. Mine was rusted too but I removed it, since I wasn't going to be hanging anything from there.
I weighed my gutted box M1010 and it came in at 6220. Once I remove the A/C off the box, that drops another 200 lbs. That was stock with 255/85-16 Toyo M/T's on aluminum rims, full tank of fuel.
My understanding is, you need to do a lift (I think 4" minimum) to be able to get a Cummins to fit and not have the oil pan sitting on the front axle. Lifting a rig and then expecting it to do heavy towing, not a good combo.
I used the existing bracket and made my own extensions to it. I suppose it would be easier if you had a second bracket but that was not an option for me. Currently mine is setup with the "Plan B" using two 12v alt but still keeping the 24v system. My plan (assuming I don't do the engine swap...
Yeah, I was surprised the difference between my current 33" tires and my old M1010 with 35" tires. I never felt like I needed an OD in my old one, with the larger tires. I have wanted to stay away from lifting my current one, so 33" was my option but added the Gear Vendor to help.
I did a 2.5" shackle flip on my old M1010 (camo colored one). I did not notice any change in handling or ride. I never got around to lifting the front, as I was going to do that after I built out the back and figure out where the end ride height was going to be. Sold the rig before I got to...
I put a headlight relay kit in, which still keeps everything at 12v but allows the lights to pull power directly from the battery. The headlight switch only controls the relays now.