Easy Tailgate Storage on the Cheap

[Hornd]

Cost: 2 stainless hinges at about $20.
Have small Aluminum angle to line the cutout. Plan to rivet it in place.
Diamond Plate top is an exact copy of carpet. C
Could attach carpet to diamond plate and make it look stock.
More pictures to follow

Cubitron II is a nasty grinding wheel! Newer Technology from 3M.

 

[half k cruiser]

 

[GW Nugget]

So is that going to be one complete large door? Or are you going to cut out a smaller door?

 

[etarasoff]

Cubitron!

 

[socallove]

Looking good!! I made mine out of aluminum too but with 3/16", I should put the carpet on too but I'm a chicken s***, afraid to cut up the carpet.

 

[half k cruiser]

@socallove where did you get the piano hinge for your lid ?

 

[socallove]

I got everything from McMaster

 

[RhinoFZJ80]

I want to make mine out of steel just to maintain the strength. Do you think the aluminium will hold up to someone standing on it?

 

[socallove]

From personal experience, Im 160# I stand and sit on it when I have too, my friend is 230# and he abuse his quite often. No issues at all! It flex a little but bounces right back.

 

[Hornd]

I want to make mine out of steel just to maintain the strength. Do you think the aluminium will hold up to someone standing on it?

It was a cart top that I stood on to remove the fastners. Obviously it was fastened all around and this will not be fastned, but I'm sure it will be strong enough. I think it's only 11ga or 1/8"

@socallove where did you get the piano hinge for your lid ?

Ebay is far cheaper! Know what you are buying. Watch out for thin Whimpy ones. Mine are stainless

Looking good!! I made mine out of aluminum too but with 3/16", I should put the carpet on too but I'm a chicken s***, afraid to cut up the carpet.

No cutting when entire top is same size as carpet. Only bad part is Hinges will be exposed.

I called shop about having a door laser cut out and they said it would be $100. I see no benefit in doing so as usable opening is same size. The nice part about this is everyone has the pattern (existing carpet).

There are some items that need to be missed when cutting the guts out of the tailgate like Linkage for Latch and wires for License Light, you can not just hog out the entire thing as I first thought.

 

[Hornd]

Making the whole thing one piece means that the entire perimeter is supported.
I'm unsure if they put a lip on inside of cut-out to support the hatch?
I will stand on it (185#) to show the deflection when complete.

 

[Hornd]

HINGE

EBAY
Seller information
bsmarinesurplus1950 (7075 )
99.6% Positive feedback
Follow this seller
Visit store:
B&S MARINE SURPLUS
See other items

Item Information
Item condition:
New other (see details)
Quantity:
More than 10 available / 86 sold
Price:
US $11.95

HUNT HINGE

STAINLESS STEEL PIANO HINGE

11" LONG 2" WIDE

GUAGE .040

PRE DRILLED:

1 "-0N 0NE SIDE

1 "- ON OTHER SIDE

FREE FRT LOWER 48 STATES

OTHERS DEPENDS ON ZIP

 

[socallove]

I went with an aluminum hinge so I can weld it for a nice clean look, counter sink bolts as well. Nothing sticking up, maybe the latch handle by 1/8" at most

 

[socallove]

Making the whole thing one piece means that the entire perimeter is supported.
I'm unsure if they put a lip on inside of cut-out to support the hatch?
I will stand on it (185#) to show the deflection when complete.

Can you post a drawing? Not understanding what how you will apply the hinge if you are using one whole piece.