convert doors into tailgate

[workingdog]

I'm going to try to do a version of this thread (thanks for leading the way) Poor Boy FJ40 tailgate and convert my doors into a tailgate because it would be so much more use to me.

I can say that splitting the back off the main panel is a HUGE pita. The spot welds around the outside edge are really hard to get at cleanly and there are areas where the main section is folded over the back pieces. It's taking a lot of time.

 

[MOTOV8R]

I split a tailgate. It took forever and some of my spot-weld cutter holes went clear through. I finally gave up on the top lip and just cut right along it on the backside and left the folded over part in tact. Keep at it, you'll get it.

 

[workingdog]

So, I can confirm that the easiest and best way to split the rear does is to use a cut off wheel and cut around the entire thing as close to the same as is practical, drill or grind out the spot welds on the raised portion, and lift it off.

Which exposes the same for easier work. In my case, I'm still going to remove most of the seam and folder over areas as the rust has gotten in there and I need to expose that part so I can get at it with POR 15. Still hours of work to do to get the seams apart, all the attachments removed, and the rust ground down, and the many, many holes welded back up - before I can even start to think about putting it back together into one piece.

Been thinking about latches. Not sure yet what I'm going to do.

 

[middlecalf]

What you doing about hinges?

 

[workingdog]

I'm hoping to do like poor boy did in the post I referenced at the beginning of this thread and re-purpose three of the side hinges to the bottom. I haven't tried laying it out yet - but that's the plan.

 

[lelandEOD]

FYI,
It's still working like a champ!

 

[workingdog]

@lelandEOD - how's that latch working? Would you do it differently?

And - who are you at war with?

 

[lelandEOD]

Nope, it works like a champ! Part of me occasionally wishes I had made it ~3" deep so that I could have built in some internal storage... but I really like how it lays flat when the tailgate is down and any thicker and it would annoy me.


The only pic have that shows the tailgate open happens to be from a MG shoot several years ago.
There's a reason I live in the desert.

Speaking of MG shoots...
...merica.

 

[Engineer8000]

When the apocalypse comes, I'm going to your house.

FYI,
It's still working like a champ!


View attachment 2160708

 

[workingdog]

@lelandEOD - where did you get the doo-dad that mounts on the tailgate that the cable connects to? I can't seem to find it - but mostly because I don't know what to call it. Also, do you remember what model and year the cable is from? It looks perfect.

 

[lelandEOD]

@lelandEOD - where did you get the doo-dad that mounts on the tailgate that the cable connects to? I can't seem to find it - but mostly because I don't know what to call it. Also, do you remember what model and year the cable is from? It looks perfect.

I found them on eBay years ago. They were advertised as either FJ40 or FJ45 tailgate brackets. I looked and don't see them listed anymore. But, they are just some laser cut pieces of 3/16" steel. You can easily sculpt a pair out of some angle iron. If you need close up pics, let me know.


For the cables, I just took some measurements once the tailgate was installed and took a few trips to the local parts houses and found a set that was the appropriate length.


....also, sorry for the minor thread hijack with the gun pics. Good luck with your project!

 

[MOTOV8R]

BTB has the tailgate pieces. Also the chain bolts for the other end and the chain. Individually or as a set.

FJ40 FJ45 Tail Gate Chain Bracket Set Short Wheel Base SWB - BTB Products - Land Cruiser Restoration and Parts

THESE CHAIN BRACKETS HAVE BEEN DISCONTINUED BY TOYOTA. THESE ARE USED TO BOLT THE CHAINS TO THE TAIL GATE. THESE ARE ANOTHER BTB DESIGNED AND TRAIL TESTED RESTORATION PRODUCT.

btbprod.com

Tail Gate Chain Bolt Set for 1958-1984 4x-Series Toyota Land Cruisers - BTB Products - Land Cruiser Restoration and Parts

Tail Gate Chain Bolt Set for 1958-1984 FJ40/FJ45 SWB Toyota Land Cruisers. These chain bolts have been discontinued by Toyota.

btbprod.com

Tail Gate Chain Kit for 1958-1984 4x-Series Toyota Land Cruisers - BTB Products - Land Cruiser Restoration and Parts

Tail Gate Chain Kit for 1958-1984 4x-Series Toyota Land Cruisers. Supplies a pair of chains, brackets, and bolts. Will not work on Long Wheel Base Cruisers.

btbprod.com

 

[lelandEOD]

BTB has the tailgate pieces. Also the chain bolts for the other end and the chain. Individually or as a set.

FJ40 FJ45 Tail Gate Chain Bracket Set Short Wheel Base SWB - BTB Products - Land Cruiser Restoration and Parts

THESE CHAIN BRACKETS HAVE BEEN DISCONTINUED BY TOYOTA. THESE ARE USED TO BOLT THE CHAINS TO THE TAIL GATE. THESE ARE ANOTHER BTB DESIGNED AND TRAIL TESTED RESTORATION PRODUCT.

btbprod.com

Tail Gate Chain Bolt Set for 1958-1984 4x-Series Toyota Land Cruisers - BTB Products - Land Cruiser Restoration and Parts

Tail Gate Chain Bolt Set for 1958-1984 FJ40/FJ45 SWB Toyota Land Cruisers. These chain bolts have been discontinued by Toyota.

btbprod.com

Tail Gate Chain Kit for 1958-1984 4x-Series Toyota Land Cruisers - BTB Products - Land Cruiser Restoration and Parts

Tail Gate Chain Kit for 1958-1984 4x-Series Toyota Land Cruisers. Supplies a pair of chains, brackets, and bolts. Will not work on Long Wheel Base Cruisers.

btbprod.com

That’s them! I’d recommend against chains (even with sleeves) since they make such a racket. I’ll take some photos of how I adapted the cables to the tub. I basically modified a pair of carriage bolts to work with the cables for the ‘quick release’ function.

 

[workingdog]

Thanks @MOTOV8R - I looked at BTB and couldn't find them. You're the best.

 

[workingdog]

Hey - So, the lower inside edge of the doors is badly pitted.

I want to POR15 all of the inside, but I also have to weld the 1x1 box tube to the inside edge as well to end up like this.

So, what do i do? How do I treat the rusted areas and still be able to weld. Do I paint with POR15 with specific areas masked out so I can weld to them?

 

[lelandEOD]

Sandblast it first. Then shoot everything with weld-through primer. Then, once the skins are attached to the frame, hit everything with POR-15.

 

[workingdog]

Thanks - sounds like a good plan. I can’t for it in my cabinet - I guess I’m filling every pore and cavity with sand again.

 

[workingdog]

Okay, I was testing fitting the doors as tailgate and looking at locating the hinges. And I realized just how out of true the rear sill is.

The whole tub is coming off in a bit to replace the quarter panels (including the upper lip) and the wheel wells, but I was hoping to keep the rear sill and the pillars on each side. But, maybe the entire thing has to go? Or do I work with it?

 

[White Stripe]

Little late to mention it, but the rear half doors are worth a fair bit of money. Real steel cruiser parts sells a really nice rear panel blank thatlooks like a factory tailgate. It would be easy to turn one into a tail gate. I have one on my cruiser.

 

[workingdog]

Okay, I made some progress. I got the frame made

It took forever, but I've got the doors ready. They were really, really beat up. Had I known I never would have used them, but it's been a great teaching experience about body work. I bought a good set of Martin hammers and dollies. As suggested, cleaned and primed with weld through primer.

Got the insert strip cut, it's a little wide, needs a little more trimming.

And got the stripped more or less welded to one side, this is my first stitch weld ever. But, I've run our of .030 welding wire and my grinder is dying. So, it's off to Harbor Freight.