how to - higher side panels on my truck

[Con]

You'll get 12 months out of standard exterior ply. I would get minimum 12mm. 15-18mm if you can afford it.

Buffalo boards are more expensive,  but will last longer.

Making a box isn't cheap, but a well made one will last the life of the van, and could be worth doing, in the long run

[Essex]

do you have a removable headboard?

No I haven’t but I’m thinking of putting something across the top at the front to stop the chip getting thrown over the top of the cab. It covers the windscreen when it rains and sits on the panel between the windscreen and the bonnet.
The marine ply on the sides has lasted a good few years and hasn’t started to delaminate yet

[Steve Bullman]

1 hour ago, Essex said:

No I haven’t but I’m thinking of putting something across the top at the front to stop the chip getting thrown over the top of the cab. It covers the windscreen when it rains and sits on the panel between the windscreen and the bonnet.
The marine ply on the sides has lasted a good few years and hasn’t started to delaminate yet

How about a sheet of Perspex over the cage, and then just tip the buck up a little when you’re chopping. Problem solved 

[Carl1991]

I'd go for some 3x2 timber uprights, 12/18mm ply on top if the alloy sides. Attach ply to frame and bolt and washer through the metal sides. Cut a piece of ply that can cover the head board but you can take out if needed, just lean it up to protect the glass. Some timber frame to make a roof and use another piece of ply, extra precaution use a ratchet strap. I'd imagine you can get that sorted for 100 quid.

 

 

 

 

[Essex]

How about a sheet of Perspex over the cage, and then just tip the buck up a little when you’re chopping. Problem solved 

I put a tarpaulin at the front over the cage when chipping to stop the chip going through the mesh at the front and tip the body up as well but bits of chip still find their way over the top. I find the advantage of using the tarp instead of Perspex is that I can take the tarp down when finished so I can see out the back for reversing. Makes life a lot easier than just relying on the two doors mirrors. For me anyway

[aspenarb]

Ply is ok but does end up looking a bit tatty, unless you brace the top or put a lid on it the sides always splay out.

 

 

 

Facing ply with Alubond  can tart it up.

 

 

 

[Gray git]

Paint it and can instantly look a whole lot better, built a ply box as a temp job on one of our vans and over a year later is still on as works absalutlely fine and still looks almost respectable, that and I haven't had time to build a ally one. [emoji57]