TAILGATE STORAGE PANEL
copypasta from my separate thread...
Tailgate storage panels have been a popular mod lately. Lots of different options from the WG lid, DIY boat hatches and several aluminum panels. The 80 series is perfect for this mod with the tailgate/hatch combo. Adam at Back Bay Customs (
@Notch) was kind enough to allow me to be a beta tester of his new tailgate panel. While they may be new in the FJ80 world they are no stranger to custom car builds:
Photo Gallery | Back Bay Customs Let's hope they continue to make products for the 80 market.
Okay on to the pics! After removing the carpet panel and the 3 access covers, temporarily attach the frame with as many bolts as you can. The frame is keyed to all the original plastic clips which makes alignment a breeze.
Place masking tape along the inside edge of the frame. This will be how you create the template for the cuts.
For the sides and rear part of the frame, place a mark 3/16" from the outside edge of the tape, where the inside edge of the frame was. For the part at the bottom of the tailgate facing the cab, you go 1/16" from the outside edge.
Mark your lines all the way around with a straight edge.
And cut! There will be 4 braces to cut through.
Here you can see the braces you will be cutting. 2 on top, 2 on bottom.
Brace.
Empty cavity.
The braces need to be trimmed back a bit for the aluminum frame that gets installed. This can be a bit tricky due to the tight space. I used a small cut off wheel and finished it off with a flap wheel on my angle grinder.
Inner aluminum frame installed after cutting away the brace.
Inner frames with rubber tape installed.
After that you're ready to attach the outer frame. The inner frames serve as a stop for the lid.
Bracket for the lift strut. Very nice.
continued...