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Tailgate lower repair progress

malcolmzilla

Bronco Guru
Joined
Mar 18, 2003
Messages
1,522
Loc.
Calgary, AB, Canada
Well the PO did a very poor patch job on my 68 tailgate, gouged out up the the middle section, plug and lip welded galvanized flashing over the rotted lower sheetmetal and posts, full of filler, it never fit well, but it being the better of the two, and me short on time and funds, and largely intact I decided to run it.

However, my bodyman, perfectionist that he is ( thats good, but bad when you're his student and always making mistakes :-X ), and without any consulation, decided to cut the patch off so that we'd have to repair it better.
"that looks like ass Malcolm - lets fix it right"
;D

So, in no particular order, heres the progress, using 2" .120 wall ERW along the bottom, slotted to make the tailgate a lift out, posts need rebuilding were rotted, and 16 ga sheetmetal for the inner and outside, had the metal shop shear it to width and broke it at my bodymans workplace (huge break as they do semi truck trailer and bus repairs).
 

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malcolmzilla

malcolmzilla

Bronco Guru
Joined
Mar 18, 2003
Messages
1,522
Loc.
Calgary, AB, Canada
Oops sorry about those 1st pics - thats the truck in progress - in hind sight should have bought a new hood, but its not a deep coat of filler, and some airbrush artist samples that i am considering to do ghost flames...

more repair pics
 

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malcolmzilla

malcolmzilla

Bronco Guru
Joined
Mar 18, 2003
Messages
1,522
Loc.
Calgary, AB, Canada
ok more tailgate...

before and after
 

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302fix

Sr. Member
Joined
Aug 17, 2004
Messages
490
Nice job.


How did you weld in the new metal? Plug weld every few inches or cut out the bad stuff and stitch weld it?
 
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malcolmzilla

malcolmzilla

Bronco Guru
Joined
Mar 18, 2003
Messages
1,522
Loc.
Calgary, AB, Canada
Cut the whole bad section out, test fit the new one, tack, adjust, retack, plug weld on the upper part of the patch and sides, seam weld to the tubing on the lower. I have better pics at home...
 
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malcolmzilla

malcolmzilla

Bronco Guru
Joined
Mar 18, 2003
Messages
1,522
Loc.
Calgary, AB, Canada
Tires are ProComp Xterrains in a 35x12.50R15 on AR767's with 3.75" backspacing. I would like to go up to 37x13.50R17 Toyo MT's... But my truck scrapes in my garage as is and another 1" of tire and 1" of body lift it won't fit... For now.
 
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