I finally got tired of boogering my rusted-out and bent stock rear swing doors. I realize that with enough caulking and duct tape anything is possible, but it was just getting rediculous. I decided that if I had to make a tailgate it would be useful for something. The whole thing is made out ouf 16 gauge sheet metal. I also didn't want to spend the $600 for the aqualu tailgate. I think I have about $50 in sheet metal and another $40 in hardware. I reused my hinges off the factory gates.
First I rolled the edges on four sides of the main panel - I didn't want any sharp edges. Boy do I wish I had a sheet metal bender. This was the same size as the original two gates when they are closed.
Then I made a 1"X5"X1" channel out of the 16 gauge sheet. I welded it to create the frame of the tailgate as well as give it the depth I wanted. This was two inches narrower and an inch shorter than the rear panel so it would allow for the latch hardware.I welded that to the rear panel.
Then I rolled the edges on another sheet, this time the size of the frame of the box. To this i attached a continuous hinge as the lid to the box.
The hardware is all off of an 89ish Toyota pickup except for the limiting straps. The tailgate closes easily, is held fast when closed. No rattles. The inner door is held in place by a paddle latch similar to those found on truck boxes.
From what I can tell I will bend my quarter panels before I bend the tailgate. It is strong. All I have left is to make a removable panel to cover the hardware inside so that when I start stuffing it full of crap it doesn't interfere with the latches. I also need to apply mud, primer and paint, but the paint will probably wait till the rest of my truck gets a coat later this summer.
The only thing I want to improve on is the lid to the compartment. I need to figure out a way to get it to lay flatter. I may have been better using two latches, but we will see.
First I rolled the edges on four sides of the main panel - I didn't want any sharp edges. Boy do I wish I had a sheet metal bender. This was the same size as the original two gates when they are closed.
Then I made a 1"X5"X1" channel out of the 16 gauge sheet. I welded it to create the frame of the tailgate as well as give it the depth I wanted. This was two inches narrower and an inch shorter than the rear panel so it would allow for the latch hardware.I welded that to the rear panel.
Then I rolled the edges on another sheet, this time the size of the frame of the box. To this i attached a continuous hinge as the lid to the box.
The hardware is all off of an 89ish Toyota pickup except for the limiting straps. The tailgate closes easily, is held fast when closed. No rattles. The inner door is held in place by a paddle latch similar to those found on truck boxes.
From what I can tell I will bend my quarter panels before I bend the tailgate. It is strong. All I have left is to make a removable panel to cover the hardware inside so that when I start stuffing it full of crap it doesn't interfere with the latches. I also need to apply mud, primer and paint, but the paint will probably wait till the rest of my truck gets a coat later this summer.
The only thing I want to improve on is the lid to the compartment. I need to figure out a way to get it to lay flatter. I may have been better using two latches, but we will see.
