tailgate repair advice

Post by **landshark** » Tue Apr 19, 2016 8:39 pm

I am working on a tailgate for my 72 and found more rust (big surprise!) after I cut off the bottom to use the replace panel - the extra rust i found is on the inside bottom where there is a embossed line which I assume is for the weatherstripping and/or strength on the flat surface. I am inclined to just cut that whole section out and replace with flat stock. Anything wrong with doing it that way? i couldn't fabricate that relief in the metal again.. i could weld in a 1/3 of round stock of some sort and maybe get close but would like to avoid warping stuff if i can.

Also what is everyone using to repair the round ends where the hinge sits? Hole saw it out and hole saw a piece of flat stock and weld it in?

Post by **Gunnibronco** » Tue Apr 19, 2016 9:27 pm

If you are worried the whole width is thin, then replace it with a flat patch. Cutting it out and patching it will give you better metal & a flange to weld or glue to.

Post by **mickphatmac** » Tue Apr 19, 2016 10:01 pm

I've seen a guy use freeze plugs that he welded into the ends.

Post by **ZOSO** » Wed Apr 20, 2016 4:42 am

You could weld in a flat piece there but just have to note that's where the seal touches the tailgate. You may then have to adjust the seal when you get to that point.

Post by **landshark** » Wed Apr 20, 2016 6:52 am

That's what I figured. I will evaluate the rot I think it would be best to remove that whole section the metal is thin in places.

Post by **plumbdoctor** » Wed Apr 20, 2016 8:24 pm

the panel I have has that raised portion included....might get one with the same style?

Post by **landshark** » Wed Apr 20, 2016 9:14 pm

plumbdoctor wrote:the panel I have has that raised portion included....might get one with the same style?

where did you get that?

Post by **casadejohnson** » Wed Apr 20, 2016 9:28 pm

yea, where? I'm in the same boat

Post by **ZOSO** » Thu Apr 21, 2016 5:11 am

casadejohnson wrote:yea, where? I'm in the same boat

Ditto x3

Post by **ZOSO** » Thu Apr 21, 2016 5:13 am

What keith has looks like the top of the tail gate.

Post by **landshark** » Thu Apr 21, 2016 6:24 am

That's what I was wondering. I might be able to cut the embossing out of that and graft it in. But not sure it's even worth it.

Post by **Dirtheadz** » Thu Apr 21, 2016 7:24 am

ive got a bead roller and could probably duplicate a similar embossing if interested

Post by **landshark** » Thu Apr 21, 2016 8:21 pm

Iam but your so far away [emoji3] let me see what I can do locally. I need to pick up a sheet of 16/18 gauge

Post by **plumbdoctor** » Fri Apr 22, 2016 3:11 pm

Its the lower, picked it up from Duff's, the only issue with it is that the raised portion goes end to end.
Gonna need some hammer and dolly work to get it to look like the stock raised portion. Over all a pretty decent piece.

Post by **plumbdoctor** » Fri Apr 22, 2016 3:14 pm

I will take a better pic tonight to show the whole thing...the pic I posted does make it look like the top piece though..

Post by **plumbdoctor** » Fri Apr 22, 2016 8:47 pm

As you can see, they rolled it all the way out to the ends, take a little work to flatten off the ends for the stock look,

Post by **landshark** » Sat Apr 23, 2016 12:36 pm

I went and bought some 17 gauge and found a shop to roll a bead on one side and bend up an approximation of the emboss. I think the thick one should work fine, I will just flatten off the ends and be done with it.

Post by **Gunnibronco** » Sat Apr 23, 2016 12:39 pm

I'm glad you are doing something to replicate it. Only because its an eyebrow tailgate. You could sell/trade up if yours comes out nice enough.

Post by **landshark** » Sun Apr 24, 2016 6:45 pm

Most of the welding is done. Took my time to make sure I didn't warp anything. Later this week I will grind the welds down, fill in any missing spots and fix the emboss on the ends so that it looks a bit more stock

Post by **Justin** » Sun Apr 24, 2016 7:01 pm

Looks great!

Post by **Gunnibronco** » Sun Apr 24, 2016 8:08 pm

Nice. Like the extra profile you added.

Post by **landshark** » Mon Apr 25, 2016 6:30 pm

Starting to grind things down. Will sand and do more later this week. Rain put a damper on my workshop time.

Post by **landshark** » Wed Apr 27, 2016 9:59 pm

Got most of the grinding done. Started working on flattening the ends of the embossing. Should have done this before i welded it in but I will make it work.

Post by **landshark** » Sun May 01, 2016 12:24 pm

a little bit of seam sealer here and there and i think its good enough for now.

Post by **phyler** » Sun May 01, 2016 12:53 pm

Looks awesome. Good work.

Sent from my HTC One using Tapatalk

Post by **landshark** » Wed May 04, 2016 7:24 pm

Installed! Ruff!

Post by **Rox Crusher** » Wed May 04, 2016 8:34 pm

landshark wrote:Installed! Ruff!

Calendar shot right there !

Post by **hockeydad4-22** » Fri May 06, 2016 1:50 pm

Otis is ready for a ride to the lake

www.ColoradoClassicBroncos.com