So as I was messing with this tailgate today, I had a thought. You know how sometimes you'll hear the current rep for some old company mention how they've been using the same recipe/tool/process/design since the beginning?
Well they're ****ing liars.
I have designed this simple 2D part about 20 times before I ever cut anything, and I've redone it a dozen times since I started test cuts. Now, I'm no engineer, for sure. I'm also not any kind of creative designer. But I have to imagine I'll sell some kits, redesign/improve, wash rinse repeat. If you get one of these next year, odds are it'll be different than one that goes out in the next few weeks.
So anyway, I completed a prototype today. Kind of. I mocked up a completed unit, at least. Here's a pic:
View attachment 3719829
Again, not an engineer, not a designer. But I'm pretty happy with this product as it sits currently. Since the photo, I taught myself some new tricks in my processing software to make the whole thing cleaner and... toighter. The lid doors now fit closer to the dimensions of the lid door openings, and I've streamlined the support lip that lives on the bottom side of the top layer. I have designed it in 2 ways- one is a full bolt together job, with 39 bolts per half and 3 shared. I also designed a weld together version, which only utilizes the original 16 push-pin holes, plus one more in the center of where the 2 halves meet.
So far I've only done this in 12ga steel, but I think 3/16 aluminum is ideal. Unfortunately, I (and many others) can't weld aluminum at home, so the bolt together version will probably be the ticket for most. Weight of the steel is somewhere around or just under 40lbs, and the aluminum should be under 30lbs.
PM me for purchase details, not going to discuss sales here as I'm not a vendor yet.
I also tried
@LJE 's trick for lowering assistance. It was a fail for me today, though. I tried using the brackets that came with my struts, but they didn't end up working. Still kicking around a bracket design in my head. If I can make that happen, that'll be another product for y'all.