The birth of an Aero Tech XT

Aero Tech XT

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We are starting to manufacture the Show Truck that we will be bringing to the Las Vegas Experience show.

Follow this thread to see how the Aero Tech XT is manufactured from the ground up.


First Stage

Chassis Box:

Dimensions: 8ft wide X 15.6ft long X 62" interior height


Here we have finished up welded the box frame. Every frame is fitted and welded in a Jig.
View attachment 2506

View attachment 2508

Moving the frame to the next process using our 5 ton overhead crane.
View attachment 2509

Getting ready to sandblast frame.
View attachment 2510

Frame has been sandblasted and is in our paint booth getting ready for paint.
View attachment 2511
 

Mikey P

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Tool cool, this should be a fun thread to watch this truck be built.


How much would just a box like that from Summit cost?

Since you took over making your own boxes is it a big savings for you or just less hassle?


On my 04 Vortex I get a lot of popping noise on bumpy roads which sound like my box shifting around a bit...
Do you fasten them down any differently these days?



FMI used 4 U bolts and 16 zip ties on mine. :eekk:
 
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Aero Tech XT

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Desk Jockey

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Cool!

Do you assemble one truck at a time or are there several built at the same time?
Is it a couple of guys doing the construction or a team of guys that only do their component?
On average how many man hours does it take to build one?
 

Aero Tech XT

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I am not sure what they go for these days since it has been about 9 years since we last purchased one.

We wanted to manufacturer our own box so we can control the quality and consistency of them. We recently got ISO 9001:2008 Certified and Compliant which helps us with that. We also knew we could make a lot of improvements.

Manufacturing our own box gives us the flexibility to customize the box in house. We have made them longer, taller, added lighting packages, extra access doors, etc.

Yes, we put a strip of plastic between the chassis frame and box frame so you don't have metal on metal contact instead of using lumber. The box is bracketed / u-bolted to the chassis frame instead of being welded. The Isuzu chassis frame is 33" wide vs. Nissan UD on your Vortex at 29.5" wide. That extra frame width also helps with flexing and the overall stability. We use a 6" aluminum extrusion on the floor instead of a 9" for extra rigidity.
 

Mikey P

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Sounds great.

Is there more or less space between the cab and box compared to my UD?


I see some cabovers around town with no space, not quite sure how they tilt the cab.
 

Jim Martin

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Sounds great.

Is there more or less space between the cab and box compared to my UD?


I see some cabovers around town with no space, not quite sure how they tilt the cab.

It is my understanding that only AT and Vortex put that space between the cab and the box........from what I was told it was because they are PTO's and sit there and idle all day....it allows it to breath and not hold heat..........

normally they are up against the cab like mine........

2008W4500026.jpg
 

Aero Tech XT

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Nope not a Cintas truck. This is the Show truck we are bringing to Las Vegas Experience show.

Box is pretty much the same.

Here is a list of some options we can do on the box:
*Wall insulation / Carpet kit (this truck will be getting this option)
*Roof insulation
*Rear roll up door
*Access Hole through FRP wall for hoses
*Recessed Exterior light above side door
*Additional height
*Longer Box
*Under-body Tool boxes (both passenger and driver side)
 

Derek

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wow that is so cool, you make the bed of the truck to. impressive setup.

how much for a new one? my single-wide is paid off in 2 more years. $400 a month extra will be burning a hole... :icon_cool:
 

Aero Tech XT

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The FRP is 1/2" thick.

The roof is arched. We roll the roof bows to prevent standing water.

Dave, do you have any before/after pics you could through up?
 

Mikey P

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thats a great video.


needs to be on their site for sure..

Every year when I gather receipts I am always surprised at how many time's I've bought parts from the AT crew for my V

ALWAYS a smooth transaction that leads to no memory of it...lol



maybe some day I"ll get a real Vortex....
 

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