Do-it-yourself board for a gazelle (drawings)

The Europlatform for GAZelle is a type of cargo superstructure designed for the transportation of Euro pallets. The internal space is calculated by optimal occupancy so that there is no empty space left.

In general, such solutions significantly increase the profitability of using freight transport when transporting palletized building materials and dry mixes.

The design looks like a classic awning and provides several options for awning the side. The base is a metal frame, which is often installed in a removable version.

Thanks to this feature, the car owner can quickly convert a covered body into an open side for transporting oversized or long cargo: equipment, fittings, lumber.

Do-it-yourself GAZelle body

An open side is one of the most popular and popular cargo platform options on the cargo transportation market. Such platforms are ideal for transporting oversized cargo and can handle the transportation of bulk materials, timber, metal structures, etc.

In addition, the open body puts minimal load on the chassis, which allows the equipment to maintain maximum load capacity.

The design is simple, so make the sides of an old or new with your own hands . This doesn't even require special knowledge. The linear dimensions of the body are calculated based on the area of the frame; the sides can be increased to the required length.

How to choose a truck awning

In the manufacture of truck awnings, modern, durable, wear-resistant materials are currently used. This made it possible to increase their service life to 10–15 years. Therefore, when buying an awning for such a significant period, it is advisable not to make a mistake and immediately purchase a quality product.

By the end of its service life, the awning material loses its elasticity and strength. It becomes easier to damage it. This process is irreversible and the situation cannot be corrected. The carrier is faced with the task of acquiring new coverage.

When replacing a truck cover, a complete or partial replacement of the bed frame or trailer is often performed. And again, you need to take a responsible approach to the choice of this structure and the material covering it.

Manufacturers of truck awnings offer products of standard shapes and sizes. On the other hand, the awning must fit perfectly into the frame of the truck or trailer bed. Therefore, it is sometimes simply impossible to find a suitable option among ready-made products. In addition, areas where the material comes into contact with the frame parts must be additionally compacted.

However, nowadays there are many companies where professionals will make an awning according to individual sizes. Measure the height, length and width of the trailer, decide what fabric you will use to make the truck cover and contact them.

Let's take a closer look at the choice of material. Today there is a truly rich assortment on the market. You can purchase inexpensive fabric from Asian manufacturers, or, if your budget allows, don’t skimp and buy an awning from a well-known European brand.

When choosing fabric for an awning, it is important to know its density. Here, as a rule, we deal with the linear mass density of the thread, which is measured in SI units in kg/m. However, the value of 1 kg/m is too high for the needs of the textile industry. Therefore, textile manufacturers traditionally use a unit of tex (TEX), equal to 1 g/km, or decitex (DTEX), which shows how many grams 10 km of thread weighs. The strength of a fabric is determined by the strength of the thread from which it is made. The strength of the thread directly depends on its density. Accordingly, by looking at the DTEX value, you can understand how strong a particular fabric will be. Therefore, when purchasing material, first of all pay attention to this parameter.

In addition to DTEX, when purchasing a material, you should find out the following characteristics of the fabric: tensile strength, tear strength, repeated bending strength, tensile strength. It is also advisable to pay attention to the properties of adhesion, color fastness, fire resistance and so on.

So, the material for the truck awning has been selected. Now everything depends on the quality of work and professionalism of the cutter. Before placing an order, observe how the potential contractor works. The nuances below will tell you a lot about the qualifications and integrity of the organization.

Fabric welding should be done only with the front side to the back, otherwise the seam will not be reliable. The edges of the truck cover must be pre-treated with a hand-held hair dryer. The measurement must be done twice. The first is done before starting work, and the second is done after the sides and roof are ready. This will allow you to make an awning that fits the truck perfectly.

What requirements must a truck awning meet:

Tarpaulin or PVC fabric is usually chosen as the material for awnings. Matter should not stretch.
The material may consist of several parts. It is necessary that the edges are overlapped. To secure, you will need two seams spaced 15 mm apart. One of the seams should be made of thread that does not match the color of the tarpaulin and is visible only from the inside.
Fastenings can be of different designs, for example:

Metal rings attached to the car;

Holes along the edges of the awning;

A rope or cable passing through the rings.

The material is put on a frame made in the form of racks, sidewalls, arches, crossbars, etc.
The distance between the fastening rings (eyes) should not exceed 180 mm. Fastenings should be made rigid.
The following are usually used as fasteners:

Steel cable with a diameter of more than 3 mm;

Hemp or similar rope with a diameter greater than 8 mm, with a transparent and non-stretchable plastic sheath.

It is unacceptable to use a cable connected from several pieces. The ends of the cable must have metal ends.

Advantages of homemade bodies

The main advantage that the factory superstructure offers the car owner is the manufacturer’s warranty. This is expressed by the fact that the exact dimensions and weight of the structure are calculated at the factory, based on maintaining the basic characteristics of the truck chassis. However, for work in real conditions, such a body often turns out to be inconvenient.

In particular, most manufacturers produce equipment with a rear unloading option. At the same time, a dump body of this format is convenient only in cases where there is room for maneuver at the unloading site.

Therefore, installing a non-standard onboard platform seems to be a more correct solution. Here, it is the owner of the equipment who determines how loading and unloading operations will be carried out, based on the range of cargo being transported and their customer base.

In particular, such a body can be:

With three-way unloading;
Extended platform;
Extended sides.

However, another difficulty arises here. It is better to carry out such alterations in a specialized auto repair shop. The fact is that any non-standard solutions require engineering calculations, which cannot be carried out efficiently in artisanal conditions.

By making the body “by eye”, the car owner runs the risk that the frame may break, unable to withstand the load. Or the equipment will simply tip over on its side if the sides are too large to overwhelm it.

Technical and design features

To make a non-standard body for a GAZelle, it is necessary to modify the chassis itself so that it matches the parameters of the modified platform. For example, if the sides are extended, the frame must be cut. In this case, the load-bearing beams are extended with special steel inserts, which are secured using riveted joints.

In addition, along with the wheelbase, auxiliary elements are lengthened:

Brake system;
Hydraulics;
Electrical;
Fuel lines;
Cardan shaft.

For three-way unloading of the platform, a more efficient pump is installed on the chassis, hydraulic cylinders are selected that will lift the body and tip the side in the desired direction.

In general, the chassis design is subject to major changes that must be registered with the traffic police. To do this, the owner will have to obtain a conclusion from a testing laboratory and the appropriate permit.

After re-equipment of equipment, a technical safety certificate is additionally issued. Only if there are no violations, the equipment is allowed to operate and the corresponding record of the alteration is made in the vehicle title.

How to remake an onboard platform on a GAZelle with your own hands?

If we are talking about a non-standard body, the work ahead is complex and painstaking. Initially, a technical specification is drawn up, within the framework of which the body structure is thought out, linear dimensions are determined, and drawings are made.

Based on the calculations made, the equipment is re-equipped. Let's look at each stage in more detail.

Dismantling

The chassis is freed from all structural elements that could interfere with the alteration. First of all, this concerns the old cargo superstructure. If the chassis is to be extended, the cardan, fuel lines and brake system are additionally removed.

The chassis is fixed, the supporting beams are cut closer to the rear overhang, usually in the area where the muffler is attached. Then extension inserts are installed.

Features of Europlatform production

In general, there are no subtleties or secrets here. Structures for transporting Euro pallets are manufactured according to the usual principle, the only difference is the variability of the side unloading.

The production process consists of the following stages:

Receiving technical specifications. Here, a technical examination is carried out to determine the possibility of converting the truck chassis. Obtaining an expert opinion is a prerequisite, otherwise difficulties are guaranteed to arise when registering equipment. Then engineering calculations are carried out and the optimal dimensions of the cargo superstructure are determined.
Preparation. In accordance with the calculations made, the frame is welded or assembled. The GAZelle frame is freed from the existing superstructure, and if necessary, the frame is extended. In this case, the fuel lines, cardan shaft, and brake system are additionally removed from the chassis.
Installation. A subframe is welded, which will provide the superstructure with maximum rigidity, help reduce vibration and evenly distribute the load on the load-bearing base. The floor is laid on top and the frame is installed. The material for the awning is cut to size and stretched onto the base. The joints are heat welded, and in the areas of PVC that will be in contact with the stiffeners, additional inserts are installed to prevent mechanical abrasion of the surface.

It should be noted here that the frame and awning are made taking into account the expected unloading of the Europlatform. This point is agreed upon with the customer and largely depends on the nature of the cargo being transported.

One of the competitive advantages of the Europlatform is the ability to unload in several projections.

In particular, the following solutions are possible here:

Rear unloading. These are swing doors with leaf latches or a flap valve.
Lateral. Sides sliding on a roller mechanism. Depending on the chosen method, such unloading can be one-sided or two-sided.
Upper. Here the roof of the superstructure moves, which also moves along the roller elements.

Thanks to this feature, Eurovans are undemanding in terms of unloading space. This is convenient in situations where access to the unloading point is limited and there is no space for maneuvering equipment.

Replacing boards

In the factory version, the body is usually equipped with metal sides. However, this is not the most durable and reliable option.

For remodeling, you can use the following solutions:

Both options feature low structural weight to help maintain chassis payload. In addition, such sides are not afraid of constant exposure to moisture, so they are guaranteed not to show signs of corrosion.

However, here you need to take into account that the aluminum and plastic sides of the GAZelle are not characterized by mechanical strength, so they are easily deformed and damaged by accidental impacts.

Frame

The design is elementary, and is a rectangle made of corrugated pipe of the required section. First, the outer frame is welded, which is connected by transverse beams. Loops for attaching the side are welded to the base.

Depending on the design features, vertical supports can be additionally installed at the corners to increase rigidity. For ease of use, such racks are usually made in a removable version.

Canvases

The modern market offers three options for canvas:

Tarpaulin.
Tarpaulin.
PVC.

Each of them has its own advantages and disadvantages. For example, tarpaulin is the most accessible and inexpensive material that tends to get wet when exposed to moisture for a long time. It is noteworthy that even the use of special impregnations does not completely solve this problem.

PVC is a denser material, neutral to humid environments and ultraviolet radiation. The service life of polyvinyl chloride is about 10-12 years, and during this period, the consumer properties of the covering material are completely preserved.

Tarpaulin is a more functional and practical analogue of PVC. Unlike polyvinyl chloride, it has a light but quite durable structure. In addition, it retains elasticity even at low subzero temperatures.

Corrosion protection

Considering that the platform turns out to be completely open, it makes sense to take care of its protection from moisture and other external influences.

To do this, all metal elements are cleaned and primed with special mastics and compounds that increase corrosion resistance. In a car workshop environment, such surfaces can be galvanized.

Flooring

To maintain load capacity, the body floor is usually made of wood.

There are two options here:

Boards followed by sheet metal cladding;
Bakelite plywood is a composite material made from multi-layer veneer, impregnated with formaldehyde resin.

Metal thickness

When repairing the GAZelle body, take into account the weight of the welded metal. After all, with each gusset and corner, the weight of the booth increases, not to mention the metal sheets. It is necessary to calculate the weight of the material used.

As for its thickness, the most optimal parameter is 2-3 millimeters. When strengthening the crossbars, you can use thicker material. In any case, it will not rot, and rust can be removed with a zinc converter if desired.

Additional reinforcement

The floor of the open body is reinforced without fail. This helps maintain structural integrity and promotes even load distribution. For reinforcement, the same profile is usually used as for the manufacture of the frame. Additional spars are welded onto potentially weak areas.

The sides of a GAZelle need to be strengthened only if they are extended.

This is done with the help of additional stiffening ribs, and helps prevent surface deformation during accidental impacts.

Also, reinforcement of the sides and floor can be done using steel gussets. The location of such elements depends on the geometry and features of the body itself.

Reinforcement of the rear side

Recommended in situations where a decision has been made to significantly increase the sides. This reinforcement is performed using an L-shaped profile, which is placed between the side pillars and the bottom of the body. However, here you need to take into account the fact that this option is only suitable for a fixed side.

Refurbishment cost

There are no fixed prices for this kind of alteration.

Prices for onboard platforms are calculated individually, taking into account the following parameters:

Complexity of design;
Material cost;
Additional equipment.

If you install the body on a GAZelle 4.2 yourself, the final cost of the work performed will be lower than when contacting a service center. However, there are no quality guarantees here either.

Therefore, regarding conversion issues, it is better to contact professionals who will not only install the platform, but also help with documentation.

Source

Materials for work

The first thing you need to find for a gazelle awning is good quality material.

If you need to completely replace the entire fabric, then you will have to choose cheaper options, but if we are talking about repairs, you can fork out a little. One of the first options that will attract the attention of many is a regular tarp. It has all the properties necessary for a good awning and is quite cheap. It stretches well, which is important for subsequent use, has a long service life, and is easy to dismantle.

Competitive PVC coatings are also worth considering. They cost exactly the same as tarpaulin, and the quality of production is about the same. According to some characteristics, PVC is much better than tarpaulin.

The third option is Tarapaulin. The physical characteristics are suitable for use as an awning, but this material reacts poorly to tension, which may affect installation in the future.

Diagram of the design of the Tarapaulin material for making an awning.
Special fabric can also be used as an awning for a gazelle. A good option is to buy rubberized fabric, for example, 202-2 PN. It is usually used for agricultural purposes, but the body can be covered with it.

Extension of the body and external frame for the awning.

It’s no secret that Gazelles have insufficient body width for loading, for example, Euro pallets and more. Euro pallet dimensions 1200 mm * 800 mm * 144 mm. Therefore, the minimum width should be at least 2050 mm if end-to-end, but the standard Gazelle has 1,975 mm only for the width of the rear side, and if there are also pillars inside, then 1,850 mm. We also offer an increase in the width of the body by moving the frame racks to the outside of the platform and manufacturing new sides and an awning. This makes it possible to load even more pallets. We are also doing this expansion. Below is a photo of a converted Gazelle with an expanded platform up to 2060 mm inside the body. The overall width of the body is 2,140 mm.

Awning repair

Less materials will be required for repair work. We will not touch on the awning frame, but as an example we will take the option with special fabric 202-2 PN. We buy additional glue for rubber and begin work. The procedure is as follows:

We remove damaged areas of the canvas and make new ones.

If necessary, we connect 2 pieces of fabric together to get a large canvas. The cut areas must be sanded and degreased. 2 canvases can be sewn with strong fishing thread or glued with rubber glue.
When using glue, you will have to make several adhesive layers for reliability. After applying the first layer of glue, wait 15 minutes, and then apply the second and glue the surfaces. Leave it all to dry for 30-40 minutes under pressure.
After drying, you can additionally sew the seams and thread to get the most reliable option.
We put the draft fabric on the frame, look, make notes in places where there is too much fabric.
Next, we sew the awning according to the overall dimensions of the Gazelle. If you need to sew several parts together, you should do it level to make everything look neater.
Each joint is stitched and then glued or vice versa.

After several fittings, the new canvas will be ready.

Extended body and new frame with awning.

We expanded the body of the Hyundai HD - 78 and now we are installing a new frame with an awning. Then the sides. The tailgate will be new, galvanized, 600 mm high. We will also replace the front shield. You need to buy long mirror brackets from Hyundai HD - 78 in Moscow somewhere. Maybe someone can tell me?

We finished this car. We made a 200 mm widened body, frame, new awning, new tailgate and front shield. We made a side loading on the left and a removable rack. They brought out the mirrors.

Rear side galvanized 600 mm.